Disposable Absorbent Article Comprising A Core With Multiple Laminates

ABSTRACT

A nonwoven web suitable for use as a secondary topsheet in disposable absorbent articles is described herein. The nonwoven web is a spunlaced, carded, staple fiber, nonwoven having a basis weight of between about 40 grams per square meter (gsm) and about 100 gsm. The nonwoven web has a plurality of absorbent fibers, a plurality of stiffening fibers and a plurality of resilient fibers, wherein the absorbent fibers makeup from about 20 percent to about 50 percent by weight, wherein the stiffening fibers makeup about 20 percent to about 40 percent by weight, wherein the resilient fibers makeup from about 25 percent to about 55 percent by weight, and wherein the carded staple fiber nonwoven is heat stiffened.

FIELD

The present invention pertains to disposable absorbent articles suitablefor absorbing and containing body exudates.

BACKGROUND

A variety of disposable absorbent articles have been relied on byconsumers to handle or manage body exudates. These consumers may includebabies, toddlers, children, teenagers, adults, and elderly persons.Thus, it is clear that the types of fluids or body exudates managed bysuch articles may vary as well to include urine, feces, menses, andother discharges. Typically, in the case of adults, the articles takethe form of sanitary napkins, adult incontinence pads, and adultincontinence diapers or undergarments. One of the primary drivers of thedesirability of these products to wearers is to give them assurance thatwhen they experience incontinence, the occurrence of such will gounnoticed by others and even more ideally by the wearers.

One way of improving the performance and overall discretion ofdisposable absorbent articles that has been widely utilized bymanufacturers has been the inclusion of superabsorbent polymers whichare able to intake increased amounts of liquid and consequently form aswollen hydrogel material. The resulting hydrogel serves to retain fluidsuch as discharged body liquids within the structure. An absorbentstructure of this type wherein hydrogel-forming materials in particulateform are incorporated into fibrous webs is disclosed in Weisman andGoldman; U.S. Pat. No. 4,610,678; issued Sep. 9, 1986.

While disposable absorbent articles with these superabsorbent materialstend to be highly absorbent and less bulky, there are a number of usersof these products that have a high body mass index (BMI) for which theseproducts still leave much to be desired. In particular, these users tendto experience exaggerated bunching of the absorbent article during wearand as a result there can be increased opportunity for leaks to occur.

Consequently, there is a need for a disposable absorbent article whichtargets to provide increased protection from leakage to consumers whichhave a high BMI while maintaining a level of discretion to the wearerwhile in use.

SUMMARY

Disposable absorbent articles in accordance with the present inventionare well suited for providing leakage protection for users thatexperience relatively small to relatively large discharges of fluids. Insome forms, a carded, staple fiber, spunlaced, nonwoven may be utilizedas a secondary topsheet in a disposable absorbent article, such as anincontinence absorbent article. The spunlaced, carded, staple fiber,nonwoven comprises a basis weight of between about 40 grams per squaremeter (gsm) and about 100 gsm, and further comprises a plurality ofabsorbent fibers, a plurality of stiffening fibers and a plurality ofresilient fibers, wherein the absorbent fibers comprise from about 20percent to about 50 percent by weight, wherein the stiffening fiberscomprise bi-component fibers at about 20 percent to about 40 percent byweight, wherein the resilient fibers comprise from about 25 percent toabout 55 percent by weight, wherein the resilient fibers comprise ahollow spiral configuration, and wherein the carded, staple fiber,spunlaced, nonwoven secondary topsheet is heat stiffened.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which the designations are used todesignate substantially identical elements and in which:

FIG. 1 is a plan view showing an exemplary embodiment of a disposableabsorbent article of the present invention, which is an incontinencepad.

FIG. 2 is a cross-sectional view of the incontinence pad shown in FIG. 1taken along 2-2.

FIG. 3 is a plan view of the pad of FIG. 1 with the primary topsheetremoved.

FIG. 4 is a cross-sectional view of the absorbent core of the pad ofFIG. 3 taken along 4-4.

FIG. 5 is a cross-sectional view of an alternate absorbent core of thepad of FIG. 2 taken along 2-2.

DETAILED DESCRIPTION

The disposable absorbent articles, particularly incontinence pads orpants, of the present invention can provide flexibility to allow for animproved and comfortable fit which is less susceptible to bunchingduring use. In particular, it is envisioned that the articles of thepresent invention exhibit heightened structural resiliency from theproposed configuration and orientation of the layers contained therein.For the purposes of this disclosure, reference to an incontinence pad,disposable absorbent article, or absorbent article will be used.However, the present invention may be applied to a plurality ofabsorbent articles including, but not limited to, sanitary napkins,pantiliners, menstrual pads, diapers, training pants, adult incontinencepants, etc.

There are several factors to consider when designing a disposableabsorbent article like an incontinence pad, particularly if improved fitand performance are desired. First, the stiffness of the pad is animportant factor. Typically, thinner pads offer less stiffness thantheir bulkier counterparts. While bulkier pads may be less likely tosuccumb to the compression that is typical during wear, bulkier pads areless desirable because they can cause the incontinence pad to lose itsdiscreetness during use. Furthermore, some flexibility in the absorbentcore can allow the incontinence pad to adjust more readily to thecontours of the body of a user during use. Second, the absorbency of thepad is key in determining whether or not the pad is useful forconsumers. Ideally, the pad is well suited to accommodate either smallor large loads of exudates. This accommodation means not only storingeither type of load sufficiently but also effectively and quicklywicking such loads from a body-contacting surface of the pad such thatthe user experiences little to no feeling of wetness after the releaseof the load. In the case of a small load, a wearer should be able tocontinue to wear the pad for some reasonable time after a release sinceimmediate changing of the pad may not be feasible or desired.

In the past, incontinence pad designs have required a bit of compromiserelative to these factors. In contrast, the absorbent articles, whichinclude but are not limited to incontinence, designed pursuant to thepresent invention account for these factors to arrive at an absorbentarticle which exhibits improved protection against leakage, particularlyfor those wearers of a higher than average body mass index (BMI).Namely, incontinence pads of the present invention provide good coreflexibility, excellent wicking, distribution, and overall absorbency,and in certain embodiments, may include barrier cuffs which stand upduring use and contact the wearer in an appropriate location areincluded as part of the construction to further protect against alikelihood of leakage from the pad.

FIG. 1 shows an absorbent article of the present invention or moreparticularly an incontinence pad or sanitary napkin 10 (referred tomainly as “incontinence pad” herein) may comprise a longitudinal axis 80and a lateral axis 90. The longitudinal axis 80 generally extendsparallel to the longest dimension of the incontinence pad 10. Thelateral axis 90 extends generally perpendicular to the longitudinal axis80 and lies in the same plane as the incontinence pad 10 in a flattenedstate on a flat surface. The lateral axis 90 bisects the length of theincontinence pad 10 where the length is parallel to the longitudinalaxis 80, and the longitudinal axis 80 bisects the width of theincontinence pad 10 where the width is parallel to the lateral axis 90.Additionally, as shown, the MD direction (machine direction) may begenerally parallel to the longitudinal axis 80 of the incontinence pad10, and the CD direction (cross-machine direction) may be generallyparallel to the lateral axis 90.

The incontinence pad 10 comprises a generally elongated oval shape.However, any suitable shape may be utilized. Some examples includehourglass (peanut), offset hourglass (one end is wider than an oppositeend and a narrowed mid-section between the ends), etc. The incontinencepad 10 may be symmetric about the longitudinal axis 80 or asymmetricabout the longitudinal axis 80. Similarly, the incontinence pad 10 maybe symmetric about the lateral axis 90 or asymmetric about the lateralaxis 90.

The incontinence pad 10 may further comprise a chassis 20 comprising aplurality of side edges 22 and 24 which extend generally parallel to thelongitudinal axis 80. A pair of end edges 26 and 28 join each of theside edges 22 and 24. One end edge 26 joins the side edges 22 and 24 inthe first end region 40 of the incontinence pad 10 while the other endedge 28 joins the side edges 22 and 24 in the second end region 48 ofthe incontinence pad 10—the second end region 48 being opposite thefirst end region 40. An intermediate region 44 is disposed between thefirst end region 40 and the second end region 48.

The chassis 20 of FIG. 1 is shown in cross-section in FIG. 2. Amongother things, the chassis 20 comprises a primary topsheet 203. Thisprimary topsheet has a body-facing surface 203A and a garment-facingsurface 203B. This chassis 20 of the pad 10 further comprises abacksheet 207 which also comprises its own body-facing surface 207A andopposing garment-facing surface 207B. These two components sandwich anabsorbent core 205. In other words, the absorbent core 205 is disposedbetween the topsheet 203 and the backsheet 207. All three components(i.e., topsheet 203, backsheet 207, and absorbent core 205) form thechassis 20 of the pad 10. Additional layers may very well be includedwithin this chassis 20, particularly between the topsheet 203 and thebacksheet 207 but it should be noted that these layers are separate andapart from the absorbent core. Suitable additional layers may includesecondary topsheets, acquisition layers, additional distribution layersover and above those which will be discussed below, and other usefullayers. In the case of a secondary topsheet, it is disposed beneath theprimary topsheet 203 and on the body-facing surface of the core. Incertain embodiments, the secondary topsheet (also known as the “STS”)has a greater length and width than the absorbent core 205.

The chassis 20 further comprises a wearer-facing surface 20A and agarment-facing surface 20B. The wearer-facing surface 20A may comprisethe topsheet 203, and the garment-facing surface 20B may comprise thebacksheet.

The absorbent core 205 is formed from multiple layers and is directed toquickly acquiring the bodily fluid or exudates and distributing themalong a length of the core. FIG. 3 depicts the absorbent core of thepresent invention as it shows a plan view of the pad 10 with the primarytopsheet 203 removed for viewing of the absorbent core 205 positionedabove the backsheet 207. FIG. 4 shows a cross-section of this absorbentcore 205 in more detail. The absorbent core 205 comprises a firstlaminate 60 which includes a first superabsorbent layer 61 disposed on afirst distribution layer 62. The first laminate 60 has an upper surface60A and a lower surface 60B which opposes the upper surface.Additionally, the first laminate 60 has a first end 66 and a second end67 which opposes the first end 66. The absorbent core 205 furtherincludes a second laminate 70 which includes a second superabsorbentlayer 71 disposed on a second distribution layer 72. This secondlaminate 70 also has an upper surface 70A and a lower surface 70B, afirst end 76, and a similar opposing second end 77. In the embodiment ofFIGS. 3 and 4, the first distribution layer 62 is joined to the seconddistribution layer 72 in an offset manner or configuration along thelength of the core. As used herein “offset” or “offset manner” meansthat the layers or laminates of interest are staggered and that theirrespective first ends or second ends are not aligned in the z-direction(i.e., the first end of one layer or laminate is not coterminous withthe second end of an adjacent underlying or overlying layer or laminate)when the layers or laminates overlay one another. This offset joinder ofthe first and second distribution layers 62, 72 results in anoverlapping and joined area of the two laminates that forms a centralportion 205C of the absorbent core 205. The central portion 205C of thecore is consequently bounded on each side by a front end portion and arear end portion 205R, both of the core. In other words, the front endportion 205F and the rear end 205R portion are respectively disposed atopposing ends of the core 205. The front end portion 205F is formed froma first end 66 or second end 67 of the first laminate 60 while the rearend portion 205F of the core 205 is formed by the first end 76 or secondend 77 of the second laminate 70. In the embodiment of FIG. 3, the firstends 66, 76 of the first and second laminates oppose each other and forma front end portion 205F and a rear end portion 205R of the absorbentcore 205, respectively. In an alternate embodiment, the second ends 67,77 of the first and second laminates may oppose each other and form afront end portion 205F and a rear end portion 205R of the absorbent core205, respectively. In both instances, the first ends 66, 76 are in theform of a male connection derived from a nested cut of the first andsecond laminates. Similarly, the second ends 67, 77 are in the form of afemale connection derived from a nested cut of the first and secondlaminates, respectively.

In an alternate embodiment, the first laminate 60 and the secondlaminate 70 may be joined to superabsorbent layer 71 instead of thesecond distribution layer. In this instance, the laminates are joined toone another in an offset manner as well except the first distributionlayer 62 is joined to the second superabsorbent layer 71 instead of thesecond distribution layer.

In one embodiment, the overlapping area or region that forms the centralportion 205C of the core 205 has at least one characteristic of agreater capacity, a greater void volume, or a greater thickness than thefront end portion 205F and the rear end portion 205F of the absorbentcore 205. This embodiment is particularly useful for providing forheightened leakage protection in the central portion where female usersof such pads would typically contact the pad and release fluids.

Applicant shall now provide more detailed insight into the individualcomponents of the disposable absorbent articles envisioned herein.

Primary Topsheet

The primary topsheet 203 (also referred to herein “topsheet”) of thechassis 20 is positioned adjacent a body-facing surface 203A of theabsorbent core 205 and may be joined thereto and to the backsheet 207 byattachment methods (not shown) such as those well known in the art.Suitable attachment methods are described with respect to joining thebacksheet 207 to the absorbent core 205. The topsheet 203 and thebacksheet 207 may be joined directly to each other in the incontinencepad periphery and may be indirectly joined together by directly joiningthem to the absorbent core 205 or additional optional layers within thechassis like a secondary topsheet which spans the entire or partial areaof the article. This indirect or direct joining may be accomplished byattachment methods which are well known in the art.

The absorbent article may comprise any known or otherwise effectiveprimary topsheet, such as one which is compliant, soft feeling, andnon-irritating to the wearer's skin. Suitable primary topsheet materialsinclude a liquid pervious material that is oriented towards and contactsthe body of the wearer permitting bodily discharges to rapidly penetratethrough it without allowing fluid to flow back through the topsheet tothe skin of the wearer. The primary topsheet, while being capable ofallowing rapid transfer of fluid through it, also provides for thetransfer or migration of the lotion composition onto an external orinternal portion of a wearer's skin. A suitable topsheet can be made ofvarious materials such as woven and nonwoven materials; apertured filmmaterials including apertured formed thermoplastic films, aperturedplastic films, and fiber-entangled apertured films; hydro-formedthermoplastic films; porous foams; reticulated foams; reticulatedthermoplastic films; thermoplastic scrims; or combinations thereof.

Apertured film materials suitable for use as the topsheet include thoseapertured plastic films that are non-absorbent and pervious to bodyexudates and provide for minimal or no flow back of fluids through thetopsheet. Nonlimiting examples of other suitable formed films, includingapertured and non-apertured formed films, are more fully described inU.S. Pat. No. 3,929,135, issued to Thompson on Dec. 30, 1975; U.S. Pat.No. 4,324,246, issued to Mullane et al. on Apr. 13, 1982; U.S. Pat. No.4,342,314, issued to Radel et al. on Aug. 3, 1982; U.S. Pat. No.4,463,045, issued to Ahr et al. on Jul. 31, 1984; U.S. Pat. No.5,006,394, issued to Baird on Apr. 9, 1991; U.S. Pat. No. 4,609,518,issued to Curro et al. on Sep. 2, 1986; and U.S. Pat. No. 4,629,643,issued to Curro et al. on Dec. 16, 1986. Commercially available formedfilmed topsheets include those topsheet materials marketed by theProcter & Gamble Company (Cincinnati, Ohio) under the DRI-WEAVE®tradename.

Nonlimiting examples of woven and nonwoven materials suitable for use asthe topsheet include fibrous materials made from natural fibers,modified natural fibers, synthetic fibers, or combinations thereof.These fibrous materials can be either hydrophilic or hydrophobic, but itis preferable that the topsheet be hydrophobic or rendered hydrophobic.As an option, portions of the topsheet can be rendered hydrophilic, bythe use of any known method for making topsheets containing hydrophiliccomponents. One such method include treating an apertured film componentof a nonwoven/apertured thermoplastic formed film topsheet with asurfactant as described in U.S. Pat. No. 4,950,264, issued to Osborn onAug. 21, 1990. Other suitable methods describing a process for treatingthe topsheet with a surfactant are disclosed in U.S. Pat. Nos. 4,988,344and 4,988,345, both issued to Reising et al. on Jan. 29, 1991. Thetopsheet may have hydrophilic fibers, hydrophobic fibers, orcombinations thereof.

A particularly suitable topsheet comprises staple length polypropylenefibers having a denier of about 1.5, such as Hercules type 151polypropylene marketed by Hercules, Inc. of Wilmington, Del. As usedherein, the term “staple length fibers” refers to those fibers having alength of at least about 15.9 mm (0.62 inches).

When the primary topsheet comprises a nonwoven fibrous material in theform of a nonwoven web, the nonwoven web may be produced by any knownprocedure for making nonwoven webs, nonlimiting examples of whichinclude spunbonding, carding, wet-laid, air-laid, meltblown,needle-punching, mechanical entangling, thermo-mechanical entangling,and hydroentangling. A specific example of a suitable meltblown processis disclosed in U.S. Pat. No. 3,978,185, to Buntin et al., issued Aug.31, 1976. The nonwoven may be compression resistant as described in U.S.Pat. No. 7,785,690 entitled “Compression Resistant Nonwovens” issued onAug. 31, 2010. The nonwoven web may have loops as described in U.S. Pat.No. 7,838,099 entitled “Looped Nonwoven Web” issued on Nov. 23, 2010.

Other suitable nonwoven materials include low basis weight nonwovens,that is, nonwovens having a basis weight of from about 18 g/m² to about25 g/m². An example of such a nonwoven material is commerciallyavailable under the tradename P-8 from Veratec, Incorporation, adivision of the International Paper Company located in Walpole, Mass.Other nonwovens are described in U.S. Pat. No. 5,792,404 and U.S. Pat.No. 5,665,452.

The topsheet may comprise tufts as described in U.S. Pat. No. 8,728,049entitled “Absorbent Article Having a Tufted Topsheet” issued on May 20,2014, U.S. Pat. No. 7,553,532 entitled “Tufted Fibrous Web” issued onJun. 30, 2009, U.S. Pat. No. 7,172,801 entitled “Tufted Laminate Web”issued on Feb. 6, 2007, or U.S. Pat. No. 8,440,286 entitled “CappedTufted Laminate Web” issued on May 14, 2013. The primary topsheet mayhave an inverse textured web as described in U.S. Pat. No. 7,648,752entitled “Inverse Textured Web” issued on Jan. 19, 2010. Tufts are alsodescribed in U.S. Pat. No. 7,410,683 entitled “Tufted Laminate Web”issued on Aug. 12, 2008.

The primary topsheet may have a pattern of discrete hair-like fibrils asdescribed in U.S. Pat. No. 7,655,176 entitled “Method of Making aPolymeric Web Exhibiting A Soft and Silky Tactile Impression” issued onFeb. 2, 2010 or U.S. Pat. No. 7,402,723 entitled “Polymeric WebExhibiting A Soft And Silky Tactile Impression” issued on Jul. 22, 2008.

The primary topsheet may comprise one or more structurally modifiedzones as described in U.S. Pat. No. 8,614,365 entitled “AbsorbentArticle” issued on Dec. 24, 2013. The primary topsheet may have one ormore out of plane deformations as described in U.S. Pat. No. 8,704,036entitled “Sanitary Napkin for Clean Body Benefit” issued on Apr. 22,2014. The primary topsheet may have a masking composition as describedin U.S. Pat. No. 6,025,535 entitled “Topsheet For Absorbent ArticlesExhibiting Improved Masking Properties” issued on Feb. 15, 2000.

Another suitable primary topsheet or a primary topsheet combined with asecondary topsheet may be formed from a three-dimensional substrate asdetailed in a U.S. provisional patent application No. 62/306,676 filedon Mar. 11, 2016 in the name of Jill M. On and entitled “AThree-Dimensional Substrate Comprising a Tissue Layer”. Thisthree-dimensional substrate has a first surface, a second surface, landareas and also comprises three-dimensional protrusions extending outwardfrom the second surface of the three-dimensional substrate, wherein thethree-dimensional protrusions are surrounded by the land areas. Thesubstrate is a laminate comprising at least two layers in a face to facerelationship, the second layer is a tissue layer facing outward from thesecond surface of the three-dimensional substrate, and the tissue layercomprises at least 80% pulp fibers by weight of the tissue layer.

The primary topsheet may have comprises one or more layers, for examplea spunbond-meltblown-spunbond material. The primary topsheet may beapertured, may have any suitable three-dimensional features, and/or mayhave a plurality of embossments (e.g., a bond pattern). The topsheet maybe apertured by overbonding a material and then rupturing the overbondsthrough ring rolling, such as disclosed in U.S. Pat. No. 5,628,097, toBenson et al., issued on May 13, 1997. Additional lateral extensibilityin the chassis 20 (i.e., in the primary topsheet and/or the backsheet)may be provided in a variety of ways. For example, either the primarytopsheet or backsheet may be pleated by any of many known methods.Alternatively, all or a portion of the chassis (i.e., also the primarytopsheet and/or backsheet) may be made of a formed web material or aformed laminate of web materials like those described in U.S. Pat. No.5,518,801 issued on 21 May 1996 in the name of Chappell et al. Such aformed web material includes distinct laterally extending regions inwhich the original material has been altered by embossing or anothermethod of deformation to create a pattern of generally longitudinallyoriented alternating ridges and valleys. The formed web material alsoincludes laterally extending unaltered regions located between thelaterally extending altered regions.

Secondary Top Sheet

As noted previously, the disposable absorbent articles of the presentdisclosure may comprise additional layers, one of which includes asecondary topsheet. As mentioned previously, the secondary topsheet maybe separate and apart from the absorbent core. Additionally, thesecondary topsheet is disposed beneath the primary topsheet 203 and onthe body-facing surface of the core. In some forms, the secondarytopsheet may have a basis weight from about 40 gsm to about 100 gsm,from about 45 gsm to about 75 gsm, or from about 50 gsm to about 60 gsm,specifically including all values within these ranges and any rangescreated thereby. In some forms, the secondary topsheet may comprise ahomogeneous mix of fibers.

In other forms, the secondary topsheet may comprise a heterogeneous mixof fibers. For example, typically a plurality of carding machines feed aspunlace process. The types of fibers supplied to the cards may behomogeneously blended as mentioned above. Or in contrast, the types offibers or the weight percentage of the fibers provided to the cardingmachines may be different. In such forms, where the types of fibersand/or the weight percentage of the fibers are varied to the cardingmachines, the resulting spunlaced structure may comprise a plurality ofheterogeneous strata which are—after the spunlacing process—integralwith one another.

For those forms where a secondary topsheet comprises a plurality ofheterogeneous strata, an acquisition gradient may be achieved withcareful selection of the fibers within each of the stratum of thesecondary topsheet. For example, a first stratum—being closest inproximity to the primary topsheet—may comprise a lower amount ofabsorbent fiber as opposed to a stratum which is disposed further fromthe primary topsheet. In such forms, the first stratum may comprise frombetween about 20 weight percent to about 30 weight percent of absorbentfiber while an opposing stratum disposed furthest from the primarytopsheet may comprise about 35 percent by weight of absorbent fiber. Insuch forms, the weight percentage of the stiffening fiber may stayconstant among the strata or may be varied to create a stiffnessgradient in the secondary topsheet in addition to the absorbencygradient. Similarly, in some forms, the resilient fibers may stayconstant among the strata or may be varied to create a permeabilitygradient in the secondary topsheet in addition to the absorbencygradient or in addition to the stiffness gradient. Forms arecontemplated where the secondary topsheets of the present disclosurecomprise between 2 to 4 strata.

Some exemplary fibers that may be included in the secondary topsheet mayinclude absorbent fibers, stiffening fibers, and resilient fibers. Formsare contemplated where at least one of the absorbent fibers, stiffeningfibers, and/or resilient fibers comprise a hydrophilic coating. Suitablehydrophilic coatings are known in the art. Additionally, in some forms,the one or more of the above fibers of the secondary topsheet maycomprise a staple length, e.g. about 38 mm.

Any suitable absorbent fibers may be utilized. Conventional absorbentfibers include cotton, \ rayon or regenerated cellulose. In somespecific forms, the secondary topsheet may comprise viscose cellulosefibers. Due to the proximity of the secondary topsheet to the topsheet,the absorbent fibers can help to pull liquid insults from the topsheetinto the absorbent core disposed beneath the secondary topsheet. In someforms, the secondary topsheet may comprise from about 20 percent toabout 50 percent by weight, from about 21 percent to about 40 percent byweight, from about 25 percent to about 30 percent by weight,specifically including any values within these ranges and any rangescreated thereby. In one specific form, the secondary topsheet maycomprise about 25 percent by weight absorbent fibers.

It is worth noting that a higher weight percentage of absorbent fibersmay be beneficial for fluid insults that are more viscous, e.g.menstrual fluid. However, the introduction of a higher weight percentageof absorbent fibers can negatively impact resiliency and stiffness ofthe secondary topsheet. And, too low of a weight percentage of absorbentfibers can result in a more ‘wet feeling’ topsheet which can create anegative impression of the product in consumers' minds. The weightpercentages provided above may work well in the context of urinary fluidinsults.

Any suitable size of absorbent fiber may be utilized. A suitable measureof size can be linked to linear density. In some forms, the absorbentfiber linear density may range from about 2 dtex to about 4 dtex, about2.5 dtex to about 3.7 dtex, or from about 2.8 dtex to about 3.5 dtex,specifically reciting all values within these ranges and any rangescreated thereby. In one specific form, the absorbent fiber may comprisea dtex of about 3.3.

The absorbent fibers may have any suitable shape. In some forms, atrilobal shape may be utilized. The trilobal shape can improve wickingand improve masking. Trilobal rayon is available from Kelheim Fibres andsold under the trade name Galaxy.

In addition to absorbent fibers, as mentioned previously, the secondarytopsheet may also comprise stiffening fibers. Stiffening fibers may beutilized to help provide structural integrity to the secondary topsheetweb material. The stiffening fibers can help increase structuralintegrity of the secondary topsheet in a machine direction and in across machine direction which facilitate web manipulation duringprocessing of the secondary topsheet for incorporation into a disposableabsorbent article. For example, the secondary topsheets of the presentdisclosure may be heat stiffened. The heat stiffening process can createa plurality of connection points amongst the stiffening fibers. Ingeneral, the higher the number of connection points, the stiffer thesecondary topsheet. So, while the creation of a plurality of connectionpoints is beneficial for processability, the creation of too manyconnection points can lead to a secondary topsheet which isuncomfortable in its respective disposable absorbent article. With thatin mind, the constituent material of the stiffening fibers, the weightpercentage of the stiffening fibers, and heat of processing should becarefully selected. The heat stiffening process is discussed hereafter.

With the foregoing in mind, any suitable stiffening fiber may beutilized. Some examples of suitable stiffening fibers includebi-component fibers comprising polyethylene and polyethyleneterephthalate components or polyethylene terephthalate andco-polyethylene terephthalate components. The components of thebi-component fiber may be arranged in a core sheath arrangement, a sideby side arrangement, an eccentric core sheath arrangement, a trilobalarrangement, or the like. In one specific example, the stiffening fibersmay comprise bi-component fibers having polyethylene/polyethyleneterephthalate components arranged in a concentric, core—sheatharrangement where the polyethylene is the sheath. In some forms,monocomponent fibers may be utilized. In such forms, the constituentmaterial of the monocomponent may comprise polypropylene.

Any suitable size of stiffening fiber may be utilized. Suitable lineardensities of stiffening fiber may be from about 4 dtex to about 12 dtex,from about 4.5 dtex to about 10 dtex, or from about 5 dtex to about 7dtex, specifically reciting all values within these ranges and anyranges created thereby. In one specific form, the stiffening fibers maycomprise 5.8 dtex polyethylene/polyethylene terephthalate bi-componentfibers arranged in a core and concentric sheath arrangement.

Any suitable weight percentage of stiffening fibers may be utilized inthe secondary topsheeet as well. However, in some forms, the secondarytopsheet of the present disclosure may be heat treated (heat stiffened).The heat treatment can create connection points amongst the fibers ofthe secondary topsheet. So, where there is a higher percentage ofstiffening fibers, more connection points may be created. The additionalconnection point can yield a much stiffer secondary topsheet which maynegatively impact comfort. In some forms, the secondary topsheet maycomprise about 20 percent to about 40 percent by weight stiffeningfibers or from about 25 percent to about 35 percent by weight stiffeningfibers, specifically including all values within these ranges and anyranges created thereby.

As noted previously, the secondary topsheet of the present disclosuremay additionally comprise resilient fibers. The resilient fibers canhelp the secondary topsheet maintain its permeability. Any suitable sizefiber may be utilized. In some forms, the resilient fibers can have alinear density of about 6 dtex to about 12 dtex, from about 8 dtex toabout 11 dtex, or from about 9 dtex to about 10 dtex, specificallyreciting all values within these ranges and any ranges created thereby.In one specific form, the resilient fibers may be comprise a lineardensity of about 10 dtex. In one specific example, the resilient fibersmay comprise 10 dtex hollow spiral polyethylene terephthalate fibers.

It is worth noting, that if smaller fiber sizes are utilized, theresiliency of the secondary topsheet would be expected to decrease. And,with the decreased size at the same weight percentage, a higher numberof fibers per gram would equate to a decrease in permeability of thesecondary topsheet. Additionally, some conventional secondary topsheetmay utilize superabsorbent polymer, e.g. AGM, to help drain theirrespective topsheets. As noted previously, AGM typically swells whenabsorbing fluid insults and can reduce permeability of secondarytopsheets by occluding openings in the secondary topsheet. However, ingeneral, conventional secondary topsheets have lower permeability whichhelps reduce the likelihood that the AGM will occlude openings of theseconventional secondary topsheets upon swelling. In contrast, due to thehigher permeability of the secondary topsheets of the presentdisclosure, AGM may not be suitable for utilization therewith withoutadditional measures ensuring that the AGM will not greatly reduce thepermeability thereof. Rather, AGM may be provided in a separate layer inan absorbent article.

Any suitable weight percentage of resilient fibers may be utilized. Insome forms, the secondary topsheet of the present disclosure maycomprise from about 25 percent to about 55 percent by weight resilientfibers, between 35 percent and 50 percent resilient fibers, or between40 percent and 45 percent by weight resilient fibers, specificallyincluding any values within these ranges and any ranges created thereby.In some specific forms, the secondary topsheet may comprise about 45percent by weight resilient fibers. In some specific forms, thesecondary topsheet may comprise about 45 percent, 10 dtex, hollow spiralpolyethylene terephthalate fibers.

With regard to the heat stiffening process, any suitable temperature maybe utilized. And, the suitable temperature may be impacted, in part, bythe constituent chemistry of the stiffening fibers as well as byprocessing speed of the secondary topsheet web. In some forms, thesecondary topsheet web may be heat stiffened at a temperature of 132degrees Celsius. It is also worth noting that in order to provide auniform stiffness property across the secondary topsheet web, anyheating operation should be set up to provide uniform heating to thesecondary topsheet web. Even small variations in temperature can greatlyimpact the tensile strength of the secondary topsheet web. For example,for two comparable secondary topsheets having a basis weight of about 50gsm, both with the above formulations, a significant difference wascreated with a small temperature difference. A heat stiffening processat 135 degrees C. yielded a CD direction tensile strength for one samplethat was twice the CD direction tensile strength of a sample subjectedto a 132 degrees C. stiffening process. A similar result was witnessedfor samples having comparable compositions and about a 70 gsm basisweight. Additionally, there was about a 1.5 times difference for the MDdirection tensile strength where the sample subjected to the highertemperature, i.e. 135 degrees C., had a higher tensile strength in theMD direction.

Data is provided below in Table 1 regarding a comparison between acommercially available secondary topsheet and a secondary topsheet ofthe present disclosure.

TABLE 1 Comparative Experimental STS Sample STS Sample Basis Weight(gsm) 75 50. Thickness (mm) — 1.05 Thickness Slitted (mm) 1.0 0.80 FluidAcquisition (s) 1.2 1.2 Rewet (g)_(—) 3.5 2 Wicking MD (mm) 25 20 Airpermeability (m³/m²/min) 250 400 Tensile strength MD (N) 25 20 Tensilestrength CD (N) 6 6 Modulus MD (N/cm) 50 50 Opacity (%) — 43

The experimental sample from the above Table 1 was a 50 gsm basis weightsecondary topsheet comprising 25 percent galaxy 3.3 dtex trilobal rayonavailable from Kelheim Fibres; 30 percent 5.8 detex PE/PET bicomponent,concentric—core/sheath—PE sheath; 45 percent, 10 dtex, 38 mm staplelength, hollow spiral polyethylene terephthalate fibers.

Backsheet

The backsheet 207 of the chassis 20 may be positioned adjacent agarment-facing surface of the absorbent core 205 and may be joinedthereto by attachment methods (not shown) such as those well known inthe art. For example, the backsheet 207 may be secured to the absorbentcore 205 by a uniform continuous layer of adhesive, a patterned layer ofadhesive, or an array of separate lines, spirals, or spots of adhesive.Alternatively, the attachment methods may comprise using heat bonds,pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any othersuitable attachment methods or combinations of these attachment methodsas are known in the art. Forms of the present disclosure are alsocontemplated wherein the absorbent core 205 is not joined to thebacksheet 207, the topsheet 203, or both.

The backsheet 207 may be impervious, or substantially impervious, toliquids (e.g., urine) and may be manufactured from a thin plastic film,although other flexible liquid impervious materials may also be used. Asused herein, the term “flexible” refers to materials which are compliantand will readily conform to the general shape and contours of the humanbody. The backsheet 207 may prevent, or at least inhibit, the exudatesabsorbed and contained in the absorbent core 205 from wetting articlesof clothing which contact the incontinence pad 10 such as undergarments.However, in some instances, the backsheet 207 may permit vapors toescape from the absorbent core 205 (i.e., is breathable) while in otherinstances the backsheet 207 may not permit vapors to escape (i.e.,non-breathable). Thus, the backsheet 205 may comprise a polymeric filmsuch as thermoplastic films of polyethylene or polypropylene. A suitablematerial for the backsheet 207 is a thermoplastic film having athickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils),for example. Any suitable backsheet known in the art may be utilizedwith the present invention.

The backsheet 207 acts as a barrier to any absorbed bodily fluids thatmay pass through the absorbent core 205 to the garment surface thereofwith a resulting reduction in risk of staining undergarments or otherclothing. Further, the barrier properties of the backsheet permit manualremoval, if a wearer so desires, of the interlabial absorbent articlewith reduced risk of hand soiling. A preferred material is a soft,smooth, compliant, liquid and vapor pervious material that provides forsoftness and conformability for comfort, and is low noise producing sothat movement does not cause unwanted sound.

The backsheet may comprise a wet laid fibrous assembly having atemporary wet strength resin incorporated therein as described in U.S.Pat. No. 5,885,265 (Osborn, III.) issued Mar. 23, 1999. The backsheetmay further be coated with a water resistant resinous material thatcauses the backsheet to become impervious to bodily fluids withoutimpairing the spreading of adhesive materials thereon.

Another suitable backsheet material is a polyethylene film having athickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils).The backsheet may be embossed and/or matte finished to provide a morecloth-like appearance. Further, the backsheet may permit vapors toescape from the absorbent core 42 (i.e., the backsheet is breathable)while still preventing body fluids from passing through the backsheet. Apreferred microporous polyethylene film which is available from TredegarCorporation, Virginia, USA, under Code No. XBF-1 12W.

For a stretchable but non-elastic backsheet, one material can be used isa hydrophobic, stretchable, spun laced, non-woven material having abasis weight of from about 30 to 40 g/m2, formed of polyethyleneterephthalate or polypropylene fibers. This material is breathable, i.e.permeable to water vapor and other gases.

For an elastic backsheet, one material which can be used is an elasticfilm sold under the trade mark EXX500 by Exxon Corporation. The materialof this film is formed from an elastomeric base composition consistingof a styrene block copolymer. However, this material is not breathable.Another material which can be used for an elastic backsheet is a plasticfilm that has been subjected to a process that provides it withelastic-like properties without attaching elastic strands to the film,and may for example comprise a formed film made in accordance with U.S.Pat. No. 4,342,314 (Radel et al) and 4463045 (Ahr et al).

Suitable breathable backsheets for use herein include all breathablebacksheets known in the art. In principle there are two types ofbreathable backsheets, single layer breathable backsheets which arebreathable and impervious to liquids and backsheets having at least twolayers, which in combination provide both breathability and liquidimperviousness. Suitable single layer breathable backsheets for useherein include those described for example in GB A 2184 389, GB A 2184390, GB A 2184 391, U.S. Pat. No. 4,591,523, U.S. Pat. No. 3,989,867,U.S. Pat. No. 3,156,242 and WO 97/24097.

The backsheet may have two layers: a first layer comprising a gaspermeable aperture formed film layer and a second layer comprising abreathable microporous film layer as described in U.S. Pat. No.6,462,251 (Cimini) issued Oct. 8, 2002. Suitable dual or multi-layerbreathable backsheets for use herein include those exemplified in U.S.Pat. No. 3,881,489, U.S. Pat. No. 4,341,216, U.S. Pat. No. 4,713,068,U.S. Pat. No. 4,818,600, EP 203 821, EP 710 471, EP 710 472, and EP 793952.

The backsheet may be a relatively hydrophobic 18 grams per square meter(gsm) spunbonded nonwoven web of 2 denier polypropylene fibers. Thebacksheet may also be a laminate as is known in the art.

The backsheet may be vapor permeable as described in U.S. Pat. No.6,623,464 (Bewick-Sonntag) issued Sep. 23, 2003 or U.S. Pat. No.6,664,439 (Arndt) issued Dec. 16, 2003. The backsheet can be formed fromany vapor permeable material known in the art. Backsheet can be amicroporous film, an apertured formed film, or other polymer film thatis vapor permeable, or rendered to be vapor permeable, as is known inthe art.

The backsheet may be a nonwoven web having a basis weight between about20 gsm and about 50 gsm. In one embodiment, the backsheet is arelatively hydrophobic 23 gsm spunbonded nonwoven web of 4 denierpolypropylene fibers available from Fiberweb Neuberger, under thedesignation F102301001. The backsheet may be coated with a non-soluble,liquid swellable material as described in U.S. Pat. No. 6,436,508(Ciammaichella) issued Aug. 20, 2002.

The backsheet has a garment-facing side and an opposite body-facingside. The garment-facing side of the backsheet comprises a non-adhesivearea and an adhesive area. The adhesive area may be provided by anyconventional means. Pressure sensitive adhesives have been commonlyfound to work well for this purpose.

Absorbent Core

The absorbent core 205 of the present invention may comprise anysuitable shape including but not limited to an oval, a discorectangle, arectangle, an asymmetric shape, and an hourglass. For example, in someforms of the present invention, the absorbent core 205 may comprise acontoured shape, e.g. narrower in the intermediate region than in theend regions. As yet another example, the absorbent core may comprise atapered shape having a wider portion in one end region of the pad whichtapers to a narrower end region in the other end region of the pad. Theabsorbent core 205 may comprise varying stiffness in the MD and CD.

As detailed earlier, the absorbent core 205 comprises a first laminateand a second laminate. Both are generally compressible, conformable,non-irritating to the wearer's skin, and capable of absorbing andretaining liquids such as urine and other certain body exudatesincluding menses.

The configuration and construction of the absorbent core 205 may vary(e.g., the absorbent core 205 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones). Further, thesize and absorbent capacity of the absorbent core 205 may also be variedto accommodate a variety of wearers. However, the total absorbentcapacity of the absorbent core 205 should be compatible with the designloading and the intended use of the disposable absorbent article orincontinence pad 10.

In some forms of the present invention, the absorbent core 205 maycomprise a plurality of multi-functional layers that are in addition tothe first and second laminates. For example, the absorbent core 205 maycomprise a core wrap (not shown) useful for enveloping the first andsecond laminates and other optional layers. The core wrap may be formedby two nonwoven materials, substrates, laminates, films, or othermaterials. In a form, the core wrap may only comprise a single material,substrate, laminate, or other material wrapped at least partially arounditself.

The absorbent core 205 of the present disclosure may comprise one ormore adhesives, for example, to help immobilize the SAP or otherabsorbent materials within the first and second laminates.

Absorbent cores comprising relatively high amounts of SAP with variouscore designs are disclosed in U.S. Pat. No. 5,599,335 to Goldman et al.,EP 1,447,066 to Busam et al., WO 95/11652 to Tanzer et al., U.S. Pat.Publ. No. 2008/0312622A1 to Hundorf et al., and WO 2012/052172 to VanMalderen. These may be used to configure the superabsorbent layers.

Additions to the core of the present disclosure are envisioned. Inparticular, potential additions to the current multi-laminate absorbentcore are described in U.S. Pat. No. 4,610,678, entitled “High-DensityAbsorbent Structures” issued to Weisman et al., on Sep. 9, 1986; U.S.Pat. No. 4,673,402, entitled “Absorbent Articles With Dual-LayeredCores”, issued to Weisman et al., on Jun. 16, 1987; U.S. Pat. No.4,888,231, entitled “Absorbent Core Having A Dusting Layer”, issued toAngstadt on Dec. 19, 1989; and U.S. Pat. No. 4,834,735, entitled “HighDensity Absorbent Members Having Lower Density and Lower Basis WeightAcquisition Zones”, issued to Alemany et al., on May 30, 1989. Theabsorbent core may further comprise additional layers that mimic thedual core system containing an acquisition/distribution core ofchemically stiffened fibers positioned over an absorbent storage core asdetailed in U.S. Pat. No. 5,234,423, entitled “Absorbent Article WithElastic Waist Feature and Enhanced Absorbency” issued to Alemany et al.,on Aug. 10, 1993; and in U.S. Pat. No. 5,147,345. These are useful tothe extent they do not negate or conflict with the effects of the belowdescribed laminates of the absorbent core of the present invention.

Laminates

The first and second laminates 60, 70 of the absorbent core 205 havebeen detailed earlier but it is important to note that these laminatesmay have cross-direction widths that are the same as each other ordifferent. For instance, the first laminate may have a lessercross-direction width than said second laminate or a greatercross-direction width than said second laminate. In certain instances,the first and second laminates have machine-direction lengths that arethe same while in other instances, the first and second laminates havemachine-direction lengths that are different. In the latter instance,the first laminate may have a lesser machine-direction length than thesecond laminate or conversely the first laminate may have a greatermachine-direction length than said second laminate.

The first and second laminates 60, 70 may further comprise an optionalintermediate layer disposed between the respective superabsorbent layerand distribution layer. This optional intermediate layer may comprisematerials detailed herein relative to the optional layers for thechassis, in general.

Additionally, although the invention requires a first and secondlaminate, the absorbent article or incontinence pad of the presentinvention may further comprise an optional laminate comprising asuperabsorbent layer and a distribution layer. This optional laminatemay take the form of a third, fourth, fifth, or even additionallaminates. The superabsorbent layer and distribution layer may exhibitthe same or different properties detailed earlier with respect to thefirst and second superabsorbent and distribution layers. This optionallaminates may be disposed on a body-facing surface of the first laminateor second laminate or on a garment-facing surface of the first laminateor second laminate.

The first and second laminates each have a first end 66, 76 that iscomplementary in shape to its respective second end 67, 77. Morespecifically, the first end 66 of the first laminate conforms shapewiseto the second end 67 of the same laminate. The same conformance appliesto the first end 76 of the second laminate relative to the second end 77of the second laminate. For instance, the first end 66 of the firstlaminate fits into the second end 67 of the first laminate. Thisconformation results from a nested cut in the laminate that providesmatching or shape fitting ends. This is also the case for the secondlaminate's respective first 76 and second ends 77. Likewise, thisfeature may also be prevalent in any optional laminates that might beincorporated into the absorbent core. This nesting or nested cut featureof the laminate allows for reduced waste of trim during manufacture. Ithas also been found that it is possible to configure the first andsecond laminates in a manner that allows for their respective first endsto oppose one another when the first and second distribution layers areoverlapped and joined forming an absorbent core with a central portion205C comprising an overlapping area. A front end portion of the core205F is formed from a first end 66, 76 of either the first laminate orthe second laminate. A rear end portion of the core 205R is similarlyformed from a first end 66, 76 of the other of the first laminate or thesecond laminate. This configuration yields an absorbent core withmatching (i.e., a male connection) ends. The first end of each laminatehas a male connection while the second end of each laminate has a femaleconnection. In such instances, the male connection of the first end fitsinto (conforms to the shape of) the female connection of the second endof the same laminate. In another embodiment, a front end portion of thecore is formed from a first end 66, 76 of either the first laminate orthe second laminate while the rear end portion of the core is formedfrom a second end 67, 77 of the other of the first laminate or secondlaminate. In this instance, the second end is shaped as a femaleconnection and therefore does not match the front end portion of thesame core. In a third embodiment, the front end portion of the core isformed from a second end of either the first laminate or the secondlaminate. A rear end portion of the core is similarly formed from asecond end of the remaining first laminate or the second laminate. Thisconfiguration yields an absorbent core with matching (i.e., a femaleconnection) ends. It should be noted, however, that the width of thefirst and second laminates may be the same or different as mentionedherein. The nested cuts of the first and second ends of each of thefirst and second laminates have shapes selected from the groupconsisting of arcs, semicircles, semi-ellipses, chevrons, rectangles,sinusoids, jigsaws, and combinations thereof.

In one embodiment, in addition to the topsheet and backsheet, the coremay comprise the first laminate having a first end which iscomplementary in shape to its respective second end and wherein saidlaminate includes a first superabsorbent layer disposed onto a firstdistribution layer and a second laminate having a first end which iscomplementary in shape to its respective second end and wherein saidlaminate includes a second distribution layer joined to a secondsuperabsorbent layer; wherein said first laminate layer is joined tosaid second laminate layer in an offset manner along a length of theabsorbent article wherein the absorbent core has a front end portionthat is formed by the first end of the second laminate.

In terms of the method of manufacture of the laminates of the presentinvention, it has been found that it is preferred to form the firstlaminate and the second laminate from a single laminate that is slitalong its machine-direction length. This method is useful only when thefirst and second superabsorbent layers are the same and the first andsecond distribution layers are the same. This sameness may be withregard to one or more of shape, basis weight, and material. The samenessof material for the distribution layer is preferred. Once the singlelaminate is slit to form the first and second laminates, these first andsecond laminates are joined. In a certain embodiment, the first andsecond laminates are joined at their respective distribution layers tothe other in an offset manner as detailed herein and may be done so viastandard mechanical, thermal, or chemical methods known to those skilledin the art.

In certain embodiments, the first or second laminates may include one ormore recessed areas that run along the machine direction or crossdirection. These recessed areas may coincide with the discontinuouspatterns of one or more of a superabsorbent layer and distributionlayer, whether it be of the first laminate, second laminate, or both.These recessed areas may also merely be formed by embossing of the firstor second laminates. These recessed areas may alternatively be formed byslitting, cutting, ring-rolling, or otherwise providing mechanicaldeformation through the first and/or second laminates. Each manner ofrecessed area formation mentioned herein is intended to yield a recessedarea that is capable of providing a point of preferential bending of theoverall article. For instance, FIG. 5 shows an alternativecross-sectional view of an absorbent core 205 at 2-2 where recessedareas 88 are either gaps or embossed channels in the first and secondlaminates 60′, 70′ of absorbent core 205, in the machine direction.These recessed areas 88 need not be present in both first and secondlaminates 60′, 70′ along the entirety of each of their lengths. Therecessed areas 88 may be present in the machine direction only in theoverlapping joinder area of the first and second laminates, 60′ 70′.Alternatively, the recessed areas 88 may be present in the in the crossdirection along the length of the first and second laminates, 60′, 70′or only in the overlapping joinder of the two laminates. In instanceslike these, the laminates through which the recessed areas are effectedwill be prone to bending more easily. In instances where a recessed area88 is present in only one of a first and second laminate, it is expectedthat there will be a preferential tendency for the pad 20 to bend at therecessed area 88. This means if the first laminate is closer to the bodythan the second laminate, the pad will likely bend away from the body.The opposite may be true as well in the event the second laminate 70′placed away from the body comprises a recessed area and the firstlaminate 60′ does not. In this instance, the pad 20 may exhibitpreferential tendency to bend toward the body. Depending on the overallconfiguration of the pad, either type of bending may be preferred in aparticular instance.

Superabsorbent Layers

The first and second superabsorbent layers 61, 71 of the first andsecond laminates 60, 70 comprise superabsorbent polymers or absorbentgelling materials (AGM). The superabsorbent layers may comprise AGMparticles or AGM fibers. In general, such AGM's have been used only fortheir fluid-absorbing properties. Such materials form hydrogels oncontact with liquid (e.g., with urine, blood, and the like). One highlypreferred type of hydrogel-forming, absorbent gelling material is basedon the hydrolyzed polyacids, especially neutralized polyacrylic acid.Hydrogel-forming polymeric materials of this type are those which, uponcontact with fluids (i.e., liquids) such as water or body fluids, imbibesuch fluids and thereby form hydrogels. In this manner, fluid dischargedinto the fluid absorbent structures herein can be acquired and held.These preferred superabsorbent polymers will generally comprisesubstantially water-insoluble, slightly cross-linked, partiallyneutralized, hydrogel-forming polymer materials prepared frompolymerizable, unsaturated, acid-containing monomers. In such materials,the polymeric component formed from unsaturated, acid-containingmonomers may comprise the entire gelling agent or may be grafted ontoother types of polymer moieties such as starch or cellulose. Thehydrolyzed polyacrylic acid grafted starch materials are of this lattertype. Thus the preferred superabsorbent polymers include hydrolyzedpolyacrylonitrile grafted starch, hydrolyzed polyacrylate graftedstarch, polyacrylates, maleic anhydride-iso-butylene copolymers andcombinations thereof. Especially preferred superabsorbent polymers arethe hydrolyzed polyacrylates and hydrolyzed polyacrylate grafted starch.

Whatever the nature of the polymer components of the preferredsuperabsorbent polymers, such materials will in general be slightlycross-linked. Cross-linking serves to render these preferredhydrogel-forming absorbent materials substantially water-insoluble, andcross-linking also in part determines the gel volume and extractablepolymer characteristics of the hydrogels formed therefrom. Suitablecross-linking agents are well known in the art and include, for example:(1) compounds having at least two polymerizable double bonds; (2)compounds having at least one polymerizable double bond and at least onefunctional group reactive with the acid-containing monomer material; (3)compounds having at least two functional groups reactive with theacid-containing monomer material; and (4) polyvalent metal compoundswhich can form ionic cross-linkages. Preferred cross-linking agents arethe di- or polyesters of unsaturated mono- or polycarboxylic acids withpolyols, the bisacrylamides and the di- or triallyl amines. Especiallypreferred cross-linking agents are N,N′-methylenebisacrylamide,trimethylol propane triacrylate and triallyl amine. The cross-linkingagent will generally comprise from about 0.001 mole percent to about 5mole percent of the preferred materials. More preferably, thecross-linking agent will comprise from about 0.01 mole percent to about3 mole percent of the absorbent gelling materials used herein.

The preferred, slightly cross-linked, hydrogel-forming absorbent gellingmaterials will generally be employed in their partially neutralizedform. For purposes described herein, such materials are consideredpartially neutralized when at least about 25 mole percent, 50 molepercent, or even 75 mole percent, of monomers used to form the polymerare acid group-containing monomers which have been neutralized with asalt-forming cation. Suitable salt-forming cations include alkali metal,ammonium, substituted ammonium and amines. This percentage of the totalmonomers utilized which are neutralized acid group-containing monomersis referred to as the “degree of neutralization.” Typically, commercialsuperabsorbent polymers have a degree of neutralization somewhat lessthan about 90%.

The preferred superabsorbent polymers used herein are those which have arelatively high capacity for imbibing fluids encountered in the fluidabsorbent articles; this capacity can be quantified by referencing the“gel volume” of said superabsorbent polymers. Gel volume can be definedin terms of the amount of synthetic urine absorbed by any given fluidabsorbent gelling agent buffer and is specified as grams of syntheticurine per gram of gelling agent.

Gel volume in synthetic urine can be determined by forming a suspensionof about 0.1-0.2 parts of dried fluid absorbent gelling material to betested with about 20 parts of synthetic urine. This suspension ismaintained at ambient temperature under gentle stirring for about 1 hourso that swelling equilibrium is attained. The gel volume (grams ofsynthetic urine per gram of fluid absorbent gelling material) is thencalculated from the weight fraction of the gelling agent in thesuspension and the ratio of the liquid volume excluded from the formedhydrogel to the total volume of the suspension. The preferredsuperabsorbent polymers useful in this invention will have a gel volumeof from about 20 to 70 grams, from about 30 to 60 grams, of syntheticurine per gram of absorbent gelling material.

The superabsorbent polymers hereinbefore described are typically used inthe form of discrete particles. Such superabsorbent polymers can be ofany desired shape, e.g., spherical or semi-spherical, cubic, rod-likepolyhedral, etc. Shapes having a large greatest dimension/smallestdimension ratio, like needles and flakes, are also contemplated for useherein. Agglomerates of fluid absorbent gelling material particles mayalso be used.

The size of the fluid absorbent gelling material particles may vary overa wide range. For reasons of industrial hygiene, average particle sizessmaller than about 30 microns are less desirable. Particles having asmallest dimension larger than about 2 mm may also cause a feeling ofgrittiness in the absorbent article, which is undesirable from aconsumer aesthetics standpoint. Furthermore, rate of fluid absorptioncan be affected by particle size. Larger particles have very muchreduced rates of absorption. Fluid absorbent gelling material particlespreferably have a particle size of from about 30 microns to about 2 mmfor substantially all of the particles. “Particle Size” as used hereinmeans the weighted average of the smallest dimension of the individualparticles.

These layers are preferably substantially free of airfelt and are thusdistinct from mixed layers that may include airfelt. As used herein,“substantially free of airfelt” means less than 5%, 3%, 1%, or even 0.5%of airfelt. In a preferred case, there will be no measurable airfelt inthe superabsorbent layers. In the case of the first superabsorbentlayer, it is preferably disposed onto the first distribution layerdiscontinuously. And as noted previously, the second superabsorbentlayer may, in conjunction with the first superabsorbent layer orindependently thereof, be disposed on the second distribution layerdiscontinuously. As used herein “discontinuously” or “in a discontinuouspattern” means that the superabsorbent polymers are applied onto thefirst distribution layer in a pattern of disconnected shaped areas.These areas of superabsorbent polymers or areas free of superabsorbentpolymer may include, but are not limited to linear strips, non-linearstrips, circles, rectangles, triangles, waves, mesh, and combinationsthereof. The first superabsorbent layer like the second superabsorbentlayer may, however, be disposed onto its respective distribution layerin a continuous pattern. As used herein “continuous pattern” or“continuously” means that the material is deposited and or secured to asuperabsorbent carrier material and/or the adjacent distribution layerin an uninterrupted manner such that there is rather full coverage ofthe distribution layer by the superabsorbent polymer.

In certain embodiments, the first and second superabsorbent layers maycomprise superabsorbent polymers that are the same. In otherembodiments, the first and second superabsorbent layers may comprisesuperabsorbent polymers that are different from one another. This is maybe in addition to the different deposition patterns that are discussedabove.

The superabsorbent layers are disposed having a thickness of 0.2 mm, 0.3mm, 0.4 mm, or 0.5 mm to 1 mm, 1.2 mm, 1.4 mm, 1.8 mm, or 2 mm. Thefirst and second superabsorbent layers may have the same or differentcross-direction widths as applied to their respective distributionlayers. For instance, the cross-direction widths of the first and secondsuperabsorbent layers may be from 20 mm, 25 mm, 30 mm, 35 mm, or 40 mmto 50 mm, 60 mm, 65 mm, 70 mm, 80 mm, or 90 mm. Alternatively, inembodiments where the widths of the first and second superabsorbentlayers differ from one another in the cross-direction width, the firstsuperabsorbent layer may have a lesser cross-direction width than thesecond superabsorbent layer. In particular, the first superabsorbentlayer may have a cross-direction width that is less than about 95%, 90%,80%, 70%, or even 60% of the width of the second superabsorbent layer.

In certain embodiments, the one or both of the first and secondsuperabsorbent layers span greater than greater than about 50%, 60%,70%, 80%, 90%, or even 95% of the cross-direction width of asuperabsorbent carrier layer and/or the respective adjoining first orsecond distribution layer.

Like the optional layers that may be included in the chassis, theabsorbent core may also comprise similar optional layers. They may bewebs selected from the group consisting of a fibrous structure, anairlaid web, a wet laid web, a high loft nonwoven, a needlepunched web,a hydroentangled web, a fiber tow, a woven web, a knitted web, a flockedweb, a spunbond web, a layered spunbond/melt blown web, a carded fiberweb, a coform web of cellulose fiber and melt blown fibers, a coform webof staple fibers and melt blown fibers, and layered webs that arelayered combinations thereof.

These optional layers of the core and of the chassis may comprisematerials such as creped cellulose wadding, fluffed cellulose fibers,airfelt, and textile fibers. The materials of the optional layers mayalso be fibers such as, for example, synthetic fibers, thermoplasticparticulates or fibers, tricomponent fibers, and bicomponent fibers suchas, for example, sheath/core fibers having the following polymercombinations: polyethylene/polypropylene, polyethylvinylacetate/polypropylene, polyethylene/polyester, polypropylene/polyester,copolyester/polyester, and the like. The optional layers may be anycombination of the materials listed above and/or a plurality of thematerials listed above, alone or in combination.

The materials of the optional layers may be hydrophobic or hydrophilicdepending on their placement within the chassis.

The materials of the optional layers may comprise constituent fiberscomprising polymers such as polyethylene, polypropylene, polyester, andblends thereof. The fibers may be spunbound fibers. The fibers may bemeltblown fibers. The fibers may comprise cellulose, rayon, cotton, orother natural materials or blends of polymer and natural materials. Thefibers may also comprise a superabsorbent material such as polyacrylateor any combination of suitable materials. The fibers may bemonocomponent, bicomponent, and/or biconstituent, non-round (e.g.,capillary channel fibers), and may have major cross-sectional dimensions(e.g., diameter for round fibers) ranging from 0.1-500 microns. Theconstituent fibers of the nonwoven precursor web may also be a mixtureof different fiber types, differing in such features as chemistry (e.g.polyethylene and polypropylene), components (mono- and bi-), denier(micro denier and >20 denier), shape (i.e., capillary and round) and thelike. The constituent fibers may range from about 0.1 denier to about100 denier.

The optional layers may include thermoplastic particulates or fibers.The materials, and in particular thermoplastic fibers, may be made froma variety of thermoplastic polymers including polyolefins such aspolyethylene (e.g., PULPEX™) and polypropylene, polyesters,copolyesters, and copolymers of any of the foregoing.

Depending upon the desired characteristics, suitable thermoplasticmaterials include hydrophobic fibers that have been made hydrophilic,such as surfactant-treated or silica-treated thermoplastic fibersderived from, for example, polyolefins such as polyethylene orpolypropylene, polyacrylics, polyamides, polystyrenes, and the like. Thesurface of the hydrophobic thermoplastic fiber may be renderedhydrophilic by treatment with a surfactant, such as a nonionic oranionic surfactant, e.g., by spraying the fiber with a surfactant, bydipping the fiber into a surfactant or by including the surfactant aspart of the polymer melt in producing the thermoplastic fiber. Uponmelting and resolidification, the surfactant will tend to remain at thesurfaces of the thermoplastic fiber. Suitable surfactants includenonionic surfactants such as Brij 76 manufactured by ICI Americas, Inc.of Wilmington, Del., and various surfactants sold under the Pegosperse™by Glyco Chemical, Inc. of Greenwich, Conn. Besides nonionicsurfactants, anionic surfactants may also be used. These surfactants maybe applied to the thermoplastic fibers at levels of, for example, fromabout 0.2 to about 1 g/cm² of thermoplastic fiber.

Suitable thermoplastic fibers may be made from a single polymer(monocomponent fibers), or may be made from more than one polymer (e.g.,bicomponent fibers). The polymer comprising the sheath often melts at adifferent, typically lower, temperature than the polymer comprising thecore. As a result, these bicomponent fibers provide thermal bonding dueto melting of the sheath polymer, while retaining the desirable strengthcharacteristics of the core polymer.

Suitable bicomponent fibers for use in the present invention may includesheath/core fibers having the following polymer combinations:polyethylene/polypropylene, polyethylvinyl acetate/polypropylene,polyethylene/polyester, polypropylene/polyester, copolyester/polyester,and the like. Particularly suitable bicomponent thermoplastic fibers foruse herein are those having a polypropylene or polyester core, and alower melting copolyester, polyethylvinyl acetate or polyethylene sheath(e.g., DANAKLON™, CELBOND™, or CHISSO™ bicomponent fibers). Thesebicomponent fibers may be concentric or eccentric. As used herein, theterms “concentric” and “eccentric” refer to whether the sheath has athickness that is even, or uneven, through the cross-sectional area ofthe bicomponent fiber. Eccentric bicomponent fibers may be desirable inproviding more compressive strength at lower fiber thicknesses. Suitablebicomponent fibers for use herein may be either uncrimped (i.e., unbent)or crimped (i.e., bent). Bicomponent fibers may be crimped by typicaltextile means such as, for example, a stuffer box method or the gearcrimp method to achieve a predominantly two-dimensional or “flat” crimp.

The length of bicomponent fibers may vary depending upon the particularproperties desired for the fibers and the web formation process.Typically, in an airlaid web, these thermoplastic fibers have a lengthfrom about 2 mm to about 12 mm long such as, for example, from about 2.5mm to about 7.5 mm long, and from about 3.0 mm to about 6.0 mm long.Nonwoven fibers may be between 5 mm long and 75 mm long, such as, forexample, 10 mm long, 15 mm long, 20 mm long, 25 mm long, 30 mm long, 35mm long, 40 mm long, 45 mm long, 50 mm long, 55 mm long, 60 mm long, 65mm long, or 70 mm long. The properties-of these thermoplastic fibers mayalso be adjusted by varying the diameter (caliper) of the fibers. Thediameter of these thermoplastic fibers is typically defined in terms ofeither denier (grams per 9000 meters) or decitex (grams per 10,000meters). Suitable bicomponent thermoplastic fibers as used in an airlaidmaking machine may have a decitex in the range from about 1.0 to about20 such as, for example, from about 1.4 to about 10, and from about 1.7to about 7 decitex.

The compressive modulus of these thermoplastic materials, and especiallythat of the thermoplastic fibers, may also be important. The compressivemodulus of thermoplastic fibers is affected not only by their length anddiameter, but also by the composition and properties of the polymer orpolymers from which they are made, the shape and configuration of thefibers (e.g., concentric or eccentric, crimped or uncrimped), and likefactors. Differences in the compressive modulus of these thermoplasticfibers may be used to alter the properties, and especially the densitycharacteristics, of the respective thermally bonded fibrous matrix.

The optional layers may also include synthetic fibers that typically donot function as binder fibers but alter the mechanical properties of thefibrous webs. Synthetic fibers include cellulose acetate, polyvinylfluoride, polyvinylidene chloride, acrylics (such as Orlon), polyvinylacetate, non-soluble polyvinyl alcohol, polyethylene, polypropylene,polyamides (such as nylon), polyesters, bicomponent fibers, tricomponentfibers, mixtures thereof and the like. These might include, for example,polyester fibers such as polyethylene terephthalate (e.g., DACRON™, andKODEL™), high melting crimped polyester fibers (e.g., KODEL™ 431 made byEastman Chemical Co.) hydrophilic nylon (HYDROFIL™), and the like.Suitable fibers may also hydrophilized hydrophobic fibers, such assurfactant-treated or silica-treated thermoplastic fibers derived from,for example, polyolefins such as polyethylene or polypropylene,polyacrylics, polyamides, polystyrenes, polyurethanes and the like. Inthe case of nonbonding thermoplastic fibers, their length may varydepending upon the particular properties desired for these fibers.Typically they have a length from about 0.3 to 7.5 cm, such as, forexample from about 0.9 to about 1.5 cm. Suitable nonbondingthermoplastic fibers may have a decitex in the range of about 1.5 toabout 35 decitex, such as, for example, from about 14 to about 20decitex.

Distribution Layers

The first and second distribution layers are useful for wicking bodilyfluids away from the skin of a wearer to facilitate comfort of continuedwear after a release. In an embodiment, the first and seconddistribution layers of the first and second laminates not only face oneanother but are joined in an offset manner to form part of the core. Thedistribution layers comprise one or more of cellulose and commuted woodpulp. This may be in the form of airlaid. The airlaid may be chemicallyor thermally bonded. In particular, the airlaid may be multi bondedairlaid (MBAL). In this instance, the distribution layer may furthercomprise a fibrous thermoplastic adhesive material at least partiallybonding the airlaid to itself and adjacent distribution layers,superabsorbent layers, or other additional (optional) layers. It shouldbe noted that the same materials that are suitable for the optionallayers of the chassis are envisioned as suitable for use in thedistribution layers. The basis weight for each of the first and seconddistribution layers range from 80 gsm, 80 gsm, 100 gsm, 110 gsm, 120gsm, or 130 gsm to 140 gsm, 150 gsm, 160 gsm, 180 gsm, 200 gsm, 220 gsm,or 240 gsm. A preferred basis weight is 135 gsm for each of thedistribution layers of the first and second laminates.

Barrier Cuffs

The incontinence pad 10 may further comprise a first barrier cuff 230Aand a second barrier cuff 230B and fastening adhesive 211 disposed onthe garment-facing surface 20B of the chassis 20. As shown, thefastening adhesive 211 may not extend out laterally to the same extentas the absorbent core 205. As such, constructions where pad curl isreduced would be beneficial.

The first barrier cuff 230A and the second barrier cuff 230B may beattached to the chassis 20 in any suitable location. For example, asshown, the first barrier cuff 230A and the second barrier cuff 230B maybe attached to a wearer-facing surface 20A of the chassis 20. As shown,the first barrier cuff 230A and the second barrier cuff 230B areattached to the primary topsheet 203. In some forms, the first barriercuff 230A and the second barrier cuff 230B may be attached to agarment-facing surface 20B of the chassis 20. For example, the firstbarrier cuff 230A and the second barrier cuff 230B may be attached tothe backsheet 207. Some examples of other suitable barrier cuffs aredescribed in U.S. Pat. No. 4,695,278; U.S. Pat. No. 4,704,115; U.S. Pat.No. 4,795,454; U.S. Pat. No. 4,909,803; U.S. Patent ApplicationPublication No. 2009/0312730.

As shown, in some forms, the first barrier cuff 230A comprises a firstcover 231 and a first elastic member 233. The second barrier cuff 230Bcomprises a second cover 235 and a second elastic member 237. As shown,the first cover 231 may fully enclose the first elastic member 233.Similarly, the second cover 235 may fully enclose the second elasticmember 237.

While the first barrier cuff 230A and the second barrier cuff 230B areshown as discrete elements which are attached to the chassis 20, anysuitable configuration may be utilized. For example, the first cover 231and/or the second cover 235 may comprise a portion of the primarytopsheet 203 and/or a portion of the backsheet 207. In such forms, thefirst barrier cuff 230A and/or the second barrier cuff 230B may beintegrally formed with the chassis 20. A form where the first barriercuff 230A and the second barrier cuff 230B are integrally formed withthe chassis 20 is shown in FIG. 2 and discussed hereafter.

Referring to FIG. 2, the first elastic member 233 and the second elasticmember 237 may be attached to the first cover 231 and the second cover235, respectively, by any suitable means. In one example, the firstelastic member may be adhesively attached to the first cover 231.Similarly, the second elastic member 237 may be adhesively attached tothe second cover 235. For example, as shown, first adhesive portions 251and 253 may attach the elastic members 233 and 237 to their respectivecovers 231 and 235. Similarly, second adhesive portions 255 and 257 mayattach their respective covers 231 and 235 to the primary topsheet 203.As described below, the first elastic member 233 and the second elasticmember 237 may be attached in only a portion the first cover 231 andsecond cover 235, respectively. Additional forms are contemplated wherethe first elastic member 233 and/or the second elastic member 237 areattached to the chassis 20 in conjunction with or independently fromtheir respective covers 231 and 235.

Referring to FIG. 2, the elastic members 233 and 237 may be disposedlaterally inboard of side edges 205A and 205B of the absorbent core 205.In other forms, the elastic members 233 and 237 may be disposedlaterally outboard of the side edges 205A and 205B of the absorbent core205. Still in other forms, the elastic members 233 and 237 may bedisposed laterally inboard of the side edges 205A and 205B of theabsorbent core 205 in the first end region 40 and the second end region48 but laterally outboard of side edges 205A and 205B of the absorbentcore 205 in the intermediate region 44. Additional forms arecontemplated where the elastic members 233 and 237 are disposedlaterally inboard of the side edges 205A and 205B of the absorbent core205 in the first end region 40 but are disposed outboard of the sideedges 205A and 205B of the absorbent core 205 in the intermediate region44 and/or the second end region 48.

The elastic members comprised by the barrier cuffs can be glued in, invarious glue lengths using various glues and glue amounts andplacements. Placement of the glue is yet another variable which shouldbe considered especially when designed with the core flexibility inmind. Gluing of the elastic members and the covers create anchor pointson the pad.

The covers of the barrier cuffs of the present invention can be made ofvarying types of nonwovens of different MD and CD flexibility. The covercan be bonded to the topsheet of the absorbent article, such as, forexample, by a slot coated stripe of adhesive, glue beads, ultrasonicsealing, or other suitable bonding agents. In certain forms of thepresent invention, the cover can be bonded to the backsheet at the sideedges 22 and 24 (see FIG. 1) of the pad, such as, for example, using acrimp or other suitable bonding agents, such as, for example, adhesive.

Elastic members may comprise any suitable elastic material. Somesuitable examples include Spandex™ or other similar polyurethanes,natural or synthetic rubber, styrene block copolymers, metallocenepolyolefins, Lycra™, or any other suitable elastomer materials known inthe art. Preferably the elastic member is durable for ease of processingand for during the use of the article and exhibits excellent elasticity(recovery after strain) even under strains as high as 400%.

Additionally, the elastic members of the present disclosure may compriseany suitable dtex. In other forms, the elastic members may comprise adtex of 680 or less. In some forms, the elastic members may have a dtexbetween 680 and 470, specifically including all numbers within the rangeand any ranges created thereby.

Minimum spacing between the first barrier cuff 230A and the secondbarrier cuff 230B may be largely driven by female anatomy. However,tradeoffs can occur where the barrier cuffs (and their respectiveelastic members) are disposed too far outboard of the absorbent core 205and too far inboard of the absorbent core 205. As such, spacing betweenthe most distal elastic members of their respective barrier cuffs shouldbe carefully selected. Starting from the narrowest width, spacingbetween the most distal elastic members of the first barrier cuff 230Aand the second barrier cuff 230B should be large enough to allowsufficient access to the absorbent core 205 during use while also takinginto account the forces which will be applied to the pad. If too narrow,access to a portion of the absorbent core 205 could be obstructed whichcould lead to leakage despite the barrier cuffs 230A and 230B. In someforms of the present invention, minimum spacing between the elasticmember of the first barrier cuff 230A and the elastic member of thesecond barrier cuff 230B which are most distal to one another may be atleast 20 mm. Any suitable spacing may be utilized. For example, in someforms of the present invention, the spacing may be greater than or equalto about 20 mm, greater than about 30 mm, greater than about 33 mm,greater than about 35 mm, greater than about 40 mm, greater than about45 mm, greater than about 50 mm, greater than about 54 mm, greater thanabout 60 mm, greater than about 65 mm, less than or equal to about 70mm, or less than about 65 mm, or less than about 60 mm, less than about55 mm, less than about 50 mm, less than about 45 mm, less than about 40mm, less than about 35 mm, less than about 30 mm, less than about 25 mm,specifically including any values within these ranges or any rangescreated thereby.

Fold Lines

Yet another factor that contributes to fit is the folds or fold lines ofthe pad. Pads generally contain one or more folds in order to make thepad more consumer friendly and easy to transport and store.Additionally, folding the pad can reduce the likelihood of elastic creepduring storage. However, these fold lines can act as bending points uponwhich elastomeric forces can act to deform the shape of the pad. And,similar to the anchor points discussed above, anchor points disposed toofar beyond a fold line can be problematic. Anchor points disposed toofar beyond a fold line can increase the torque lever arm acting on thepad in the MD direction causing pad curl and/or the pad to fold backinto the folded state.

Referring back to FIG. 1, incontinence pad 10 may further comprise afirst fold line 50 and a second fold line 55. The first fold line 50 candefine a boundary between the first end region 40 and the intermediateregion 44. The second fold line 55 can define a boundary between thesecond end region 48 and the intermediate region 44. The first endregion 40 can be defined by the end edge 26, the first fold line 50, anda portion of the side edges 22 and 24 disposed between the end edge 26and the first fold line 50. The intermediate area 44 can be by the firstfold line 50, the second fold line 55, and a portion of the side edges22 and 24 disposed between the first fold line 50 and second fold line55. The second end region 48 is defined by the second fold line 55, endedge 28, and a portion of the side edges 22 and 24 disposed between theend edge 28 and the second fold line 55. The fold lines 50 and 55 can beparallel and can be co-linear (on average) with the folds which arecreated via the packaging process for the incontinence pad 10.

In some forms, the first fold line 50 and second fold line 55, may beconfigured such that the fold lines 50 and 55 dissect the pad intothirds. In other forms, the first fold line 50 may be offset toward theend edge 28, and the second fold line 55 may be offset toward the endedge 28. In such forms, this can allow the second end region 48 to betucked between the intermediate region 44 and the first end region 40when the pad is in the folded configuration.

Additional Features

In some forms of the present invention, the incontinence pads orsanitary napkins may comprise wings. Wings can provide additionalleakage protection for the incontinence pad and can help secure the padto the underwear of the user. Any suitable wing configuration known inthe art may be utilized.

All the components can be adhered together with adhesives, including hotmelt adhesives, as is known in the art. The adhesive can be FindlayH2128 UN or Savare PM 17 and can be applied using a Dynafiber HTWsystem.

Per FIG. 2, during use, the pad can be held in place by any support orattachment suitable for such purposes. In certain forms of the presentinvention, the pad is placed in the user's undergarment or panty andsecured thereto by the fastening adhesive 211. The fastening adhesive211 secures the pad in the crotch portion of the user's panty. A portionor all of the garment-facing surface 20B of the chassis 20 is coatedwith fastening adhesive 211. Any adhesive or glue suitable for suchpurposes can be used for the fastening adhesive 211 herein, such as, forexample, using pressure-sensitive adhesive. Suitable adhesives include,for example, Century A-305-IV manufactured by the Century AdhesivesCorporation of Columbus, Ohio; and Instant Lock 34-2823 manufactured bythe National Starch and Chemical Company of Bridgewater, N.J. Suitableadhesive fasteners are also described in U.S. Pat. No. 4,917,697. Beforethe absorbent article is placed in use, the pressure-sensitive adhesiveis typically covered with a removable release liner in order to keep theadhesive from drying out or adhering to a surface other than the crotchportion of the panty prior to use. Suitable release liners are alsodescribed in U.S. Pat. Nos. 4,917,697 and 4,556,146. Any commerciallyavailable release liners commonly used for such purposes can be utilizedherein. Non-limiting examples of suitable release liners are BL30MG-ASilox E1/0 and BL30MG-A Silox 4P/O both of which are manufactured by theAkrosil Corporation of Menasha, Wis. The pad can be used by removing therelease liner and thereafter placing the absorbent article in a panty sothat the adhesive contacts the panty. The adhesive maintains theabsorbent article in its position within the panty during use. Therelease liner can also be a wrapper that can individually package thepad.

Again, although the majority of discussion herein is around incontinencepads and sanitary napkins, it is envisioned that this invention is alsouseful for taped diapers, training pants which pull on, adultincontinence diapers and pants, and replaceable pads for incontinenceand menses collection that might be inserted and removed after use in adisposable or durable panty or underpant.

Test Methods

Table 2 below shows Inda/Edana Nonwoven Standard Procedures standardizedtest methods which can be utilized to measure the metrics listed inTable 1.

TABLE 2 The determination of fiber composition and weight percentagethereof can be determined via ISO 1833-2013. Measured Metric MethodBasis Weight WSP130.1 Thickness WSP120.6, load 0.5 kpa Thickness SlittedWSP120.6, load 0.5 kpa Fluid Acquisition WSP70.7, 3^(rd) strike RewetWSP70.8, after 3^(rd) strike Wicking MD NWSP010.1.R0(15) Tensilestrength MD Based on ASTM D76 Tensile strength CD Based on ASTM D76

EXAMPLES Example 1

An incontinence pad or sanitary napkin approximately 270 mm long havingan hourglass shape is constructed. It has a maximum width of 92 mm and awidth of 78 mm in the center of the length. The product has 2 fold linesalong its length. The layers are adhesively combined using appropriatehotmelt adhesives known in the art. The outer perimeter is crimped (viaheat and pressure). The pad includes the following components:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet which is continuous in MD and ˜59 mm wide in    the CD and formed from a material of 45% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers    (5.8 dtex), 25% tri-lobal rayon fibers (3.3 dtex).-   3) Absorbent core which includes at least the following two    laminates.    -   a) First laminate is 39 mm wide×200 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 40 mm in a male connection shape and        complementing the shape of the second end of the same laminate        which is a female connection. Hence, the first and second ends        mate. The first superabsorbent layer is formed from an AGM        carrier material of 10 gsm SMS PP hydrophilic coated nonwoven        (39 mm wide) and a layer of superabsorbent particles (AGM) which        is 28 mm wide with AGM free areas approximately 10 mm square        arranged throughout the first laminate are formed where a total        of 1.25 g total AGM is utilized thereon. The first        superabsorbent layer is joined to an airlaid material (160 gsm)        comprised of pulp (˜82.5%), bico fiber (˜15%) and latex (2.5%)        at 39 mm wide.    -   b) A second laminate is 59 mm wide×200 mm long on a longitudinal        axis or centerline. The first end of the second laminate        exhibits nested cutting with a radius of 40 mm in a male        connection shape and complementing the shape of the second end        of the same laminate which takes a female connection shape. The        second distribution layer comprises an airlaid material (160        gsm) comprised of pulp (˜82.5%), bico fiber (˜15%) and latex        (2.5%) at 59 mm wide. The second superabsorbent layer comprise        an AGM carrier material of 10 gsm SMS PP hydrophilic coated        nonwoven which is 59 mm wide and thereon is disposed a layer of        superabsorbent particles (AGM) at 48 mm wide in a continuous        pattern in the MD and CD with a total of 2.14 g of AGM.

The first and second laminates are arranged with first and seconddistribution layers contacting and opposing first (male connection orconvex) ends of the first and second laminates forming the ends of theresultant pad with a total length from a front end portion to a rear endportion along the longitudinal axis of 251 mm.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glued continuously in MD to the topsheet at    a spacing of 40 mm) and having an inner to inner spacing of about 34    mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    60% each and glued for 120 mm (attachment approximately 85 mm from    leading and 65 mm from trailing edge). Inner to inner elastic    spacing of about 41 mm and spacing of about 4 mm between each strand    in each cuff.

Example 2

An incontinence pad or sanitary napkin approximately 348 mm long havingan hourglass shape is constructed. It has a maximum width of 106 mm anda width of 88 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet having the same characteristics as that in    Example 1.-   2) Secondary topsheet which is 75 gsm continuous in MD and ˜72 mm    wide in the CD. homogeneous blend of (a) 25% hollow, spiral PET    fibers (10 dtex, 38 mm staple length), (b) 35% tri-lobal rayon    fibers (3.3 dtex, 38 mm length), and (c) 40% round PP fibers (1.7    dtex, 38 mm length). The primary topsheet and secondary topsheet are    mechanically combined as detailed in U.S. Provisional Patent    Application No. 62/306,676, filed on Mar. 11, 2016 in the name of    Jill M. Orr.-   3) Absorbent core which includes at least the following two    laminates.    -   a) A rectangular first laminate is 49 mm wide×230 mm long (on a        longitudinal axis or centerline). All layers of the laminate are        this full length. The first superabsorbent layer is formed from        an AGM carrier material of 10 gsm SMS PP nonwoven (49 mm wide)        and a layer of superabsorbent particles (AGM) which is 49 mm        wide disposed continuously on the carrier material with a total        AGM amount of 2.81 g. The first superabsorbent layer is joined        to an airlaid material (120 gsm) comprised of pulp (˜82.5%),        bico fiber (˜15%) and latex (2.5%) at 49 mm wide.

b) A second laminate is 69 mm wide×288 mm long on a longitudinal axis orcenterline. The second distribution layer comprises an airlaid material(120 gsm) comprised of pulp (˜82.5%), bico fiber (˜15%) and latex (2.5%)at 59 mm wide. The second superabsorbent layer comprise an AGM carriermaterial of 10 gsm SMS PP nonwoven which is 114 mm wide and thereon isdisposed a layer of superabsorbent particles (AGM) at 61 mm wide in acontinuous pattern in the MD and CD with AGM free areas of 10 mm squarethroughout the layer and a total of 4.3 g of AGM.

The first and second laminates are joined with the distribution layerscontacting and joined to one another and such that they are aligned inboth the CD and MD of the pad. Alternatively, they can be overlapped ina central portion of the core only and spread along a longitudinal axisof the product to reach the desired product length.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 62 mm and glued intermittently for about 63 mm at the    ends of the product with a 50 mm spacing) and having an inner to    inner spacing of about 44 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 170 mm (attachment approximately 99 mm from    leading and 80 mm from trailing edge). Inner to inner elastic    spacing of about 51 mm and spacing of about 4 mm between each strand    in each cuff.

Example 3

An incontinence pad or sanitary napkin approximately 348 mm long havingan hourglass shape is constructed. It has a maximum width of 106 mm anda width of 88 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet having the same characteristics as that in    Example 1.-   2) Secondary topsheet having the same characteristics as that in    Example 2 and is mechanically combined with the primary topsheet in    Example 2.-   3) Absorbent core which includes at least the following two    laminates.    -   a) A rectangular first laminate is 69 mm wide×288 mm long (on a        longitudinal axis or centerline). All layers of the laminate are        this full length. The first superabsorbent layer is formed from        an AGM carrier material of 10 gsm SMS PP nonwoven (114 wide) and        a layer of superabsorbent particles (AGM) which is 50 mm wide        disposed continuously on the carrier material in the MD and CD        with a total AGM amount of 3.59 g leaving a 5 mm gap on one side        of the laminate and a 14 mm gap on the other side, both in        the CD. The first superabsorbent layer is joined to an airlaid        material (135 gsm) comprised of pulp (˜82.5%), bico fiber (˜15%)        and latex (2.5%) at 69 mm wide.

b) A second laminate is formed which is the same as the first laminate.

The first and second laminates are arranged and joined to one anotherwith the distribution layers facing each other and the respectivematching gaps on the respective superabsorbent layers aligned with oneanother in the CD. The laminates should be aligned in the center of theproduct in the MD and CD.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 62 mm and glued intermittently for about 63 mm at the    ends of the product with a 50 mm spacing) and having an inner to    inner spacing of about 44 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 170 mm (attachment approximately 99 mm from    leading and 80 mm from trailing edge). Inner to inner elastic    spacing of about 51 mm and spacing of about 4 mm between each strand    in each cuff.

Example 4

An incontinence pad or sanitary napkin approximately 400 mm long havingan hourglass shape is constructed. It has a maximum width of 119 mm anda width of 98 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) A primary topsheet having the same characteristics as that in    Example 1.-   2) A secondary topsheet which is continuous in MD and ˜59 mm wide in    the CD and formed from a material of 45% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers    (5.8 dtex), 25% tri-lobal rayon fibers (3.3 dtex).-   3) Absorbent core which includes at least the following two    laminates.    -   a) First laminate is 59 mm wide×310 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 51.6 mm in a male connection shape        complementing the shape of the second end of the same laminate        which is a female connection. Hence, the first and second ends        mate with one another. The first superabsorbent layer is formed        from an AGM carrier material of 10 gsm SMS PP nonwoven (59 mm        wide) and a layer of superabsorbent particles (AGM) which is 28        mm wide with AGM free areas approximately 10 mm square arranged        throughout the first laminate are formed where a total of 4.55 g        total AGM is utilized thereon. The first superabsorbent layer is        joined to an airlaid material (135 gsm) comprised of pulp        (˜82.5%), bico fiber (˜15%) and latex (2.5%) at 59 mm wide.    -   b) A second laminate is 79 mm wide×310 mm long on a longitudinal        axis or centerline. The first end of the second laminate        exhibits nested cutting with a radius of 51.6 mm in a male        connection shape and complementing the female connection shape        of the second end of the same laminate. The second distribution        layer comprises an airlaid material (120 gsm) comprised of pulp        (˜82.5%), bico fiber (˜15%) and latex (2.5%) at 79 mm wide. The        second superabsorbent layer comprise an AGM carrier material of        10 gsm SMS PP nonwoven which is 79 mm wide and thereon is        disposed a layer of superabsorbent particles (AGM) at 71 mm wide        in a continuous pattern in the MD and CD with a total of 5.7 g        of AGM.

The first and second laminates are arranged with the distribution layerscontacting and joined with opposing first ends of each laminate whichhave male connection or convex shapes forming the respective ends of theresultant pad. This pad has a total length from a front end portion to arear end portion along the longitudinal axis of 381 mm.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 72 mm and glued intermittently for about 87 mm at the    ends of the product with a 60 mm spacing) and having an inner to    inner spacing of about 54 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 195 mm (attachment approximately 113 mm from    leading and 93 mm from trailing edge). Inner to inner elastic    spacing of about 61 mm and spacing of about 4 mm between each strand    in each cuff.

Example 5

An incontinence pad or sanitary napkin approximately 348 mm long havingan hourglass shape is constructed. It has a maximum width of 106 mm anda width of 88 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet which is 75 gsm continuous in MD and ˜72 mm    wide in the CD. homogeneous blend of (a) 25% hollow, spiral PET    fibers (10 dtex, 38 mm staple length), (b) 35% tri-lobal rayon    fibers (3.3 dtex, 38 mm length), and (c) 40% round PP fibers (1.7    dtex, 38 mm length). The primary topsheet and secondary topsheet are    mechanically combined as detailed in Example 2-   3) Absorbent core which includes at least the following two    laminates.    -   a) First laminate is 59 mm wide×288 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 46.5 mm in a male connection shape and        complementing the shape of the second end the same laminate        which has a female connection. Hence, the first and second ends        mate. Both the front end portion and rear end portions of the        core have male (or convex) connection shapes. The first        superabsorbent layer is formed from an AGM carrier material of        10 gsm SMS PP nonwoven (59 mm wide) and a layer of        superabsorbent particles (AGM) which is 59 mm wide with AGM        disposed in a continuous pattern thereon in the CD and MD with a        total of 4.3 g used. The first superabsorbent layer is joined to        an airlaid material (135 gsm) comprised of pulp (˜82.5%), bico        fiber (˜15%) and latex (2.5%) at 59 mm wide.    -   b) A second laminate is 69 mm wide×288 mm long on a longitudinal        axis or centerline. The first end of the second laminate        exhibits nested cutting with a radius of 46.5 mm in a male        connection shape complementing the shape of the second end of        the same laminate which has a female connection. The second        distribution layer comprises an airlaid material (135 gsm)        comprised of pulp (˜82.5%), bico fiber (˜15%) and latex (2.5%)        at 59 mm wide. The second superabsorbent layer comprise an AGM        carrier material of 10 gsm SMS PP nonwoven which is 114 mm wide        and thereon is disposed a layer of superabsorbent particles        (AGM) at 61 mm wide in a pattern with AGM free areas that are 10        mm square across the layer in the MD and CD with a total of 4.3        g of AGM.

The first and second laminates are arranged in the center of the productin an overlapping manner in the MD with opposing male connection orconvex ends, a total length from a front end portion to a rear endportion along the longitudinal axis of 329 mm.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff—nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 62 mm and glued intermittently for about 63 mm at the    ends of the product with a 50 mm spacing) and having an inner to    inner spacing of about 44 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 170 mm (attachment approximately 99 mm from    leading and 80 mm from trailing edge). Inner to inner elastic    spacing of about 51 mm and spacing of about 4 mm between each strand    in each cuff.

Example 6

A diaper is approximately 400 mm with leg holes cut and removed from thechassis. The CD outermost edges are seamed to form a waist loop. Achassis of the diaper includes the following components:

-   1) Primary topsheet which is 15 gsm PP Spunbond Nonwoven with    hydrophilic surfactant treatment. This topsheet material is 400 mm    long.-   2) Secondary topsheet which is 250 mm in MD and 75 mm wide in the CD    and comprises a material of 45% hollow, spiral PET fibers (10 dtex,    38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers (5.8 dtex),    25% tri-lobal rayon fibers (3.3 dtex). A front edge of this STS is    placed 50 mm from the front of the diaper and it is centered in the    CD.-   3) Optional layer suitable for acquisition is 250 mm long and 70 mm    in CD is centered on the STS. Curly pulp fibers of this layer are    created by surface crosslinking pulp fibers.-   4) Absorbent core which includes two laminates as detailed herein.    -   a) A first laminate of 49 mm wide×250 mm long (on a longitudinal        axis) where all materials in this laminate are full length. The        first laminate exhibits nested cutting with a trapezoidal shape        (in thirds, first and third section are 30 degree angle to a        transverse axis and middle third allow the transverse axis) with        the “male” connection (convex) facing the rear of the product.        The first superabsorbent layer includes an AGM carrier material        of 10 gsm SMS PP nonwoven (69 mm wide and wrapped around one        side of the first laminate and flush with the other side. The        superabsorbent particles are disposed on the carrier material in        a 38 mm wide area with AGM free areas that measure approximately        10 mm square arranged over an area of the carrier and/or        laminate with a total of 4 g AGM. The first distribution layer        comprises an airlaid material (160 gsm) which includes pulp        (˜82.5%), bico fiber (˜15%) and latex (2.5%) at 49 mm wide.    -   b) A second laminate measuring 89 mm wide×250 mm long has nested        cutting with a trapezoidal shape (in thirds, first and third        section are 30 degree angle to the transverse axis and middle        third allow the transverse axis) with the “male” side (convex)        facing the front of the diaper. The second distribution layer        includes an airlaid material (160 gsm) of pulp (˜82.5%), bico        fiber (˜15%) and latex (2.5%) at 89 mm wide. The second        superabsorbent layer includes a layer of superabsorbent polymer        particles (AGM) in a 78 mm wide continuous pattern in MD and CD        with a total of 8 g of AGM. This AGM is deposited on an AGM        carrier material of 10 gsm SMS PP nonwoven (109 mm wide wrapped        around one side of the laminate and flush with the other side).

The laminates are arranged with opposing male ends, total length fromone end to other end on the longitudinal centerline is 310 mm (withfront edge 25 mm from the front edge of the product).

-   5) A backsheet which is 25 gsm polypropylene film (breathable);-   6) A nonwoven covering on the backsheet (garment facing side) of 25    gsm Spunbond PE/PP bico.-   7) A barrier cuff—nonwoven first cover/second cover each having a    basis weight of 14 gsm (glued continuously in MD to the topsheet at    a spacing of 90 mm) and having an inner to inner spacing of about 74    mm (continuing to CD edges).-   8) A barrier—cuff—elastic members of Lycra®—2 strands per cuff each    having 680 dtex stretched about 150% each and glued for 220 mm    (attachment approximately 70 mm from rear and 45 mm from front    edge). Inner to inner elastic spacing of about 70 mm and spacing of    about 4 mm between each strand in each cuff.-   9) An outer chassis (known in the art for diapers/disposable pants)    of an elasticized laminate of 18 gsm Bico (PE/PP sheath core) on    either side of a vacuum formed film consisting of styrenic block    copolymer elastic material activated by means well known in the art    like ring-rolling.

Example 7

An incontinence pad or sanitary napkin approximately 270 mm long havingan hourglass shape is constructed. It has a maximum width of 92 mm and awidth of 78 mm in the center of the length. The product has 2 fold linesalong its length. The layers are adhesively combined using appropriatehotmelt adhesives known in the art. The outer perimeter is crimped (viaheat and pressure). The pad includes the following components:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet which is continuous in MD and 59 mm wide in    the CD and formed from a material of 45% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers    (5.8 dtex), 25% tri-lobal rayon fibers (3.3 dtex).-   3) Absorbent core which includes at least the following two    laminates.    -   a) First laminate is 39 mm wide×200 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 40 mm in a male connection shape and        complementing the shape of the second end of the same lamiate        which is a female connection. Hence, the first and second ends        mate. The first superabsornbent layer is formed from an AGM        carrier material of 10 gsm SMS PP nonwoven (39 mm wide) and a        layer of superabsorbent particles (AGM) which is 28 mm wide with        AGM free areas approximately 10 mm square arranged throughout        the first laminate are formed where a total of 1.25 g total AGM        is utilized thereon. The first superabsorbent layer is joined to        an airlaid material (160 gsm) comprised of pulp (82.5%), bico        fiber (15%) and latex (2.5%) at 39 mm wide.    -   b) A second laminate is 59 mm wide×200 mm long on a longitudinal        axis or centerline. The first end of the second laminate        exhibits nested cutting with a radius of 40 mm in a male        connection shape and complementing the shape of the second end        of the same laminate which takes a female connection shape. The        second distribution layer comprises an airlaid material (120        gsm) comprised of pulp (82.5%), bico fiber (15%) and latex        (2.5%) at 59 mm wide. The second superabsorbent layer comprise        an AGM carrier material of 10 gsm SMS PP nonwoven which is 59 mm        wide and thereon is disposed a layer of superabsorbent particles        (AGM) at 48 mm wide in a continuous pattern in the MD and CD        with a total of 2.14 g of AGM.

The first and second laminates are arranged with first and seconddistribution layers contacting and opposing first (male connection orconvex) ends of the first and second laminates forming the ends of theresultant pad with a total length from a front end portion to a rear endportion along the longitudinal axis of 251 mm.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glued continuously in MD to the topsheet at    a spacing of 40 mm) and having an inner to inner spacing of about 34    mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    60% each and glued for 120 mm (attachment approximately 85 mm from    leading and 65 mm from trailing edge). Inner to inner elastic    spacing of about 41 mm and spacing of about 4 mm between each strand    in each cuff.

Example 8

An incontinence pad or sanitary napkin approximately 348 mm long havingan hourglass shape is constructed. It has a maximum width of 106 mm anda width of 88 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet which is continuous in MD and 69 mm wide in    the CD and formed from a material of 45% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers    (5.8 dtex), 25% tri-lobal rayon fibers (3.3 dtex). It is    mechanically combined with the primary topsheet.-   3) Absorbent core which includes at least the following two    laminates.    -   a) A first laminate is 50 mm wide×288 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of about 46.5 mm in a male connection        shape complementing the shape of a second end of the same        laminate which is a female connection. A superabsorbent layer is        formed from an AGM carrier material of 10 gsm SMS PP nonwoven        (50 mm wide) and a layer of superabsorbent particles (AGM) which        is 38.5 mm wide with AGM free areas about 10 mm square        throughout the layer with a total AGM amount of 2.91 g. The        first superabsorbent layer is joined to an airlaid material (160        gsm) comprised of pulp (82.5%), bico fiber (15%) and latex        (2.5%) at 50 mm wide.    -   b) A second laminate is formed which is 68 mm wide×288 mm long.        The first end of the second laminate exhibits nested cutting        with the same radius as the first laminate and also has        complementary female connection second ends. A superabsorbent        layer is formed from the same AGM carrier material of the first        laminate but which is 68 mm wide and a layer of superabsorbent        particles which is 61 mm wide with AGM free areas of about 10 mm        square throughout the layer with a total of 4.27 g total AGM.        The second superabsorbent layer is joined to the same airlaid        material as the first laminate but with a width of 59 mm.

The first and second laminates are centered longitudinally, overlappedin the machine direction (with male connection first ends facing outwardin the MD) such that the combined structure of the two laminates is 329mm long. The laminates are joined to one another with the distributionlayers facing each other and the respective matching gaps on therespective superabsorbent layers aligned with one another in the CD. Thelaminates should be aligned in the center of the product in the MD andCD.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 62 mm and glued intermittently for about 63 mm at the    ends of the product with a 50 mm spacing) and having an inner to    inner spacing of about 44 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 170 mm (attachment approximately 99 mm from    leading and 80 mm from trailing edge). Inner to inner elastic    spacing of about 51 mm and spacing of about 4 mm between each strand    in each cuff.

Example 9

An incontinence pad or sanitary napkin approximately 348 mm long havingan hourglass shape is constructed. It has a maximum width of 106 mm anda width of 88 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet which is continuous in MD and 59 mm wide in    the CD and formed from a material of 45% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers    (5.8 dtex), 25% tri-lobal rayon fibers (3.3 dtex). It is    mechanically combined with the primary topsheet.-   3) Absorbent core which includes at least the following two    laminates.    -   a) A first laminate is 50 mm wide×264 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of about 46.5 mm in a male connection        shape complementing the shape of a second end of the same        laminate which is a female connection. A superabsorbent layer is        formed from an AGM carrier material of 10 gsm SMS PP nonwoven        (50 mm wide) and a layer of superabsorbent particles (AGM) which        is 38.5 mm wide with AGM free areas about 10 mm square        throughout the layer with a total AGM amount of 2.91 g. The        first superabsorbent layer is joined to an airlaid material (160        gsm) comprised of pulp (82.5%), bico fiber (15%) and latex        (2.5%) at 59 mm wide.    -   b) A second laminate is formed which is 68 mm wide×264 mm long.        The first end of the second laminate exhibits nested cutting        with the same radius as the first laminate and also has        complementary female connection second ends. A superabsorbent        layer is formed from the same AGM carrier material of the first        laminate but which is 68 mm wide and a layer of superabsorbent        particles which is 61 mm wide with AGM free areas of about 10 mm        square throughout the layer with a total of 4.27 g total AGM.        The second superabsorbent layer is joined to the same airlaid        material as the first laminate but with a width of 59 mm.

The first and second laminates are centered longitudinally, overlappedin the machine direction (with male connection first ends facing outwardin the MD) such that the combined structure of the two laminates is 329mm long. The laminates are joined to one another with the distributionlayers facing each other and the respective matching gaps on therespective superabsorbent layers aligned with one another in the CD. Thelaminates should be aligned in the center of the product in the MD andCD.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 62 mm and glued intermittently for about 68 mm at the    ends of the product with a 50 mm CD spacing) and having an inner to    inner spacing of about 44 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 170 mm (attachment approximately 99 mm from    leading and 80 mm from trailing edge). Inner to inner elastic    spacing of about 51 mm and spacing of about 4 mm between each strand    in each cuff.

Example 10

An incontinence pad or sanitary napkin approximately 348 mm long havingan hourglass shape is constructed. It has a maximum width of 106 mm anda width of 88 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet is continuous in MD and 72 mm wide in the CD    and formed from a homogeneous blend of 25% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 35% tri-lobal rayon fibers (3.3    dtex, 38 mm length), and 40% round PP fibers (1.7 dtex, 38 mm    length). It is mechanically combined with the primary topsheet with    solid state formation with a 0.0135″ depth of engagement from    ring-rolling.-   3) Absorbent core which includes at least the following two    laminates.    -   a) A first laminate is 49 mm wide×230 mm long in a rectangular        shape where all materials in the laminate are full length and        full width. A superabsorbent layer is formed from an AGM carrier        material of 10 gsm SMS PP nonwoven (49 mm wide) and a layer of        superabsorbent particles (AGM) which is 49 mm wide and        continuously applied in the MD and CD with a total AGM amount of        2.81 g. The first superabsorbent layer is joined to an airlaid        material (135 gsm) comprised of pulp (82.5%), bico fiber (15%)        and latex (2.5%) at 49 mm wide.    -   b) A second laminate is formed just as the first laminate is        formed but is applied upside down. It is 69 mm wide×288 mm long        in a rectangular shape. A superabsorbent layer is formed from        the same AGM carrier material of the first laminate but which is        114 mm wide and a layer of superabsorbent particles which is 61        mm wide and continuous in the MD and CD with AGM free areas of        about 10 mm square throughout the layer with a total of 4.3 g of        total AGM. The second superabsorbent layer is joined to the same        airlaid material as the first laminate this airlaid has a width        of 59 mm.

The first and second laminates are centered in the MD and CD and laidone on top of another. The laminates are joined to one another with thedistribution layers facing each other and the respective matching gapson the respective superabsorbent layers aligned with one another in theCD.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 62 mm and glued intermittently for about 63 mm at the    ends of the product with a 50 mm CD spacing) and having an inner to    inner spacing of about 44 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 170 mm (attachment approximately 99 mm from    leading and 80 mm from trailing edge). Inner to inner elastic    spacing of about 51 mm and spacing of about 4 mm between each strand    in each cuff.

Example 11

An incontinence pad or sanitary napkin approximately 400 mm long havingan hourglass shape is constructed. It has a maximum width of 119 mm anda width of 98 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet which is continuous in MD and 79 mm wide in    the CD and formed from a material of 45% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers    (5.8 dtex), 25% tri-lobal rayon fibers (3.3 dtex). It is    mechanically combined with the primary topsheet.-   3) Absorbent core which includes at least the following two    laminates.    -   a) First laminate is 50.5 mm wide×339 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 51.6 mm in a male connection shape        complementing the shape of the second end of the same laminate        which is a female connection. Hence, the first and second ends        mate with one another. The first superabsorbent layer is formed        from an AGM carrier material of 10 gsm SMS PP nonwoven 70 mm        wide (including 11 mm wrapped around the airlaid material on one        side) and a layer of superabsorbent particles (AGM) which is        38.5 mm wide with AGM free areas approximately 10 mm square        arranged throughout the first laminate are formed where a total        of 4.55 g total AGM is utilized thereon. The first        superabsorbent layer is joined to an airlaid material (135 gsm)        comprised of pulp (82.5%), bico fiber (15%) and latex (2.5%) at        59 mm wide.

b) A second laminate is 77.5 mm wide×339 mm long on a longitudinal axisor centerline. The first end of the second laminate exhibits nestedcutting with a radius of 51.6 mm in a male connection shape andcomplementing the female connection shape of the second end of the samelaminate. The second distribution layer comprises an airlaid material(135 gsm) comprised of pulp (82.5%), bico fiber (15%) and latex (2.5%)at 79 mm wide. The second superabsorbent layer comprise an AGM carriermaterial of 10 gsm SMS PP nonwoven which is 90 mm wide (including 11 mmmaterial wrapped around back side of airlaid material) and thereon isdisposed a layer of superabsorbent particles (AGM) at 65.5 mm wide in acontinuous pattern in the MD and CD with a total of 5.7 g of AGM.

The first and second laminates are arranged with the distribution layerscontacting and joined with opposing first ends of each laminate whichhave male connection or convex shapes forming the respective ends of theresultant pad. This pad has a total length from a front end portion to arear end portion along the longitudinal axis of 381 mm.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 72 mm and glued intermittently for about 87 mm at the    ends of the product with a 60 mm spacing) and having an inner to    inner spacing of about 54 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 195 mm (attachment approximately 113 mm from    leading and 93 mm from trailing edge). Inner to inner elastic    spacing of about 61 mm and spacing of about 4 mm between each strand    in each cuff.

Example 12

An incontinence pad or sanitary napkin approximately 400 mm long havingan hourglass shape is constructed. It has a maximum width of 119 mm anda width of 98 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

-   1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core)    nonwoven with hydrophilic surfactant treatment and a printed quilted    pattern.-   2) Secondary topsheet which is continuous in MD and 59 mm wide in    the CD and formed from a material of 45% hollow, spiral PET fibers    (10 dtex, 38 mm staple length), 30% Sheath/Core PE/PET Bico Fibers    (5.8 dtex), 25% tri-lobal rayon fibers (3.3 dtex). It is    mechanically combined with the primary topsheet.-   3) Absorbent core which includes at least the following two    laminates.    -   a) First laminate is 59 mm wide×310 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 51.6 mm in a male connection shape        complementing the shape of the second end of the same laminate        which is a female connection. Hence, the first and second ends        mate with one another. The first superabsorbent layer is formed        from an AGM carrier material of 10 gsm SMS PP nonwoven (59 mm        wide) and a layer of superabsorbent particles (AGM) which is 59        mm wide with AGM free areas approximately 10 mm square arranged        throughout the first laminate are formed where a total of 4.55 g        total AGM is utilized thereon. The first superabsorbent layer is        joined to an airlaid material (135 gsm) comprised of pulp        (82.5%), bico fiber (15%) and latex (2.5%) at 39 mm wide.    -   b) A second laminate is 79 mm wide×310 mm long on a longitudinal        axis or centerline. The first end of the second laminate        exhibits nested cutting with a radius of 51.6 mm in a male        connection shape and complementing the female connection shape        of the second end of the same laminate. The second distribution        layer comprises an airlaid material (135 gsm) comprised of pulp        (82.5%), bico fiber (15%) and latex (2.5%) at 79 mm wide. The        second superabsorbent layer comprise an AGM carrier material of        10 gsm SMS PP nonwoven which is 79 mm wide and thereon is        disposed a layer of superabsorbent particles (AGM) at 71 mm wide        in a continuous pattern in the MD and CD with a total of 5.7 g        of AGM.

The first and second laminates are arranged with the distribution layerscontacting and joined with opposing first ends of each laminate whichhave male connection or convex shapes forming the respective ends of theresultant pad. This pad has a total length from a front end portion to arear end portion along the longitudinal axis of 381 mm.

-   4) A backsheet comprises a 14 gsm polypropylene film.-   5) A barrier cuff nonwoven first cover/second cover each having a    basis weight of 15 gsm (glue continuously in MD to the topsheet with    a spacing of 72 mm and glued intermittently for about 87 mm at the    ends of the product with a 60 mm spacing) and having an inner to    inner spacing of about 54 mm (continuing to CD edges);-   6) Barrier cuff elastic members or strands are formed from Lycra®.    There are 2 strands per cuff each having 470 dtex stretched about    80% each and glued for 195 mm (attachment approximately 113 mm from    leading and 93 mm from trailing edge). Inner to inner elastic    spacing of about 61 mm and spacing of about 4 mm between each strand    in each cuff.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A spunlaced, carded, staple fiber, nonwovenhaving a basis weight of between about 40 grams per square meter (gsm)and about 100 gsm, the spunlaced, carded, staple fiber, nonwovencomprising a plurality of absorbent fibers, a plurality of stiffeningfibers and a plurality of resilient fibers, wherein the absorbent fiberscomprise from about 20 percent to about 50 percent by weight, whereinthe stiffening fibers comprise bi-component fibers at about 20 percentto about 40 percent by weight, wherein the resilient fibers comprisefrom about 25 percent to about 55 percent by weight, wherein theresilient fibers comprise a hollow spiral configuration, and wherein thecarded staple fiber nonwoven is heat stiffened.
 2. The spunlaced,carded, staple fiber, nonwoven of claim 1, wherein the hollow spiralresilient fibers comprise polyethylene terephthalate (PET) and have alinear density of about 6 dtex to about 12 dtex.
 3. The spunlaced,carded, staple fiber, nonwoven of claim 1, wherein the stiffening fiberscomprise bi-component fibers arranged in a core-sheath configuration, aside-by-side configuration, or trilobal configuration.
 4. The spunlaced,carded, staple fiber, nonwoven of claim 3, wherein constituent materialsof the bi-component fibers are selected from at least two ofpolyethylene, polyethylene terephthalate, and co-polyethyleneterephthalate.
 5. The spunlaced, carded, staple fiber, nonwoven of claim3, wherein the bi-component fibers are arranged in a core-sheathconfiguration and the sheath comprises polyethylene, and the corecomprises polyethylene terephthalate.
 6. The spunlaced, carded, staplefiber, nonwoven of claim 1, wherein the stiffening fibers comprisebi-component fibers arranged in a core-sheath configuration, wherein thesheath comprise polypropylene, and the core comprises polyethyleneterephthalate, wherein the stiffening fibers have a linear density ofbetween about 4 dtex to about 12 dtex, and are present at about 25percent to about 32 percent by weight.
 7. The spunlaced, carded, staplefiber, nonwoven of claim 6, wherein the stiffening fibers are present atabout 30 percent by weight, and wherein the stiffening fibers have alinear density of about 5.8 dtex.
 8. The spunlaced, carded, staplefiber, nonwoven of claim 2, wherein the resilient fibers are present atabout 35 percent to about 50 percent by weight and have a linear densityranging from 8 dtex to 11 dtex.
 9. The spunlaced, carded, staple fiber,nonwoven of claim 2, wherein the resilient fibers are present at about40 percent to about 45 percent by weight and a linear density rangingfrom 9 dtex to about 10 dtex.
 10. The spunlaced, carded, staple fiber,nonwoven of claim 2, wherein the resilient fibers are present at about45 percent and a linear density of about 10 dtex.
 11. The spunlaced,carded, staple fiber, nonwoven of claim 6, wherein the resilient fibersare present at about 45 percent and a linear density of about 10 dtex.12. The spunlaced, carded, staple fiber, nonwoven of claim 1, whereinthe absorbent fibers are present at about 21 percent to about 40 percentby weight and comprise rayon.
 13. The spunlaced, carded, staple fiber,nonwoven of claim 1, wherein the absorbent fibers are present at about25 percent to about 30 percent by weight.
 14. The spunlaced, carded,staple fiber, nonwoven of claim 12, wherein the absorbent fibers have alinear density of about 2 dtex to about 4 dtex.
 15. The spunlaced,carded, staple fiber, nonwoven of claim 12, wherein the absorbent fibershave a linear density of about 2.5 dtex to about 3.7 dtex.
 16. Thespunlaced, carded, staple fiber, nonwoven of claim 12, wherein theabsorbent fibers have a linear density of about 2.8 dtex to about 3.5dtex.
 17. The spunlaced, carded, staple fiber, nonwoven of claim 1,wherein the absorbent fibers are present at about 25 percent by weight,comprise a linear density of about 3.3 dtex, and have a trilobalcross-section.
 18. The spunlaced, carded, staple fiber, nonwoven ofclaim 1, wherein the spunlaced, carded, staple fiber, nonwoven is heatstiffened at a temperature of 132 degrees C.
 19. The spunlaced, carded,staple fiber, nonwoven of claim 1, wherein the plurality of fibers ofthe secondary topsheet are homogeneously mixed in the secondarytopsheet.
 20. The spunlaced, carded, staple fiber, nonwoven of claim 1,wherein the spunlaced, carded, staple fiber, nonwoven comprises aplurality of strata, wherein each of the strata comprise a heterogeneousfiber mixture compared to one another.
 21. An absorbent articlecomprising a topsheet, a backsheet, an absorbent core disposed betweenthe topsheet and the backsheet, and the spunlaced, carded, staple fiber,nonwoven of claim 1 disposed between the topsheet and the absorbentcore.